Paper 2 - Set A Solutions: General Instructions

Paper 2 Set A Solutions
Regn No: _________________

Name: ___________________
(To be written by the candidates)
NATIONAL CERTIFICATION EXAMINATION 2006

FOR
ENERGY MANAGERS & ENERGY AUDITORS
PAPER 2:
Energy Efficiency in Thermal Utilities
Date: 22.04.2006
Timings: 1400-1700 HRS
Duration: 3 HRS
Max. Marks: 150
General instructions:
o
o
o
o
o
Please check that this question paper contains 8 printed pages

Please check that this question paper contains 65 questions
The question paper is divided into three sections
All questions in all three sections are compulsory
All parts of a question should be answered at one place
Section I: OBJECTIVE TYPE

(i)
(ii)
(iii)
1.
Answer all 50 questions

Each question carries one mark
Put a () tick mark in the appropriate box in the answer book
Which of the following is not measured in ultimate analysis?

a) carbon
2.
b) decreases
c) remains same
d) none of the above
b) Sulphur
c) Hydrogen
for complete
d) Methane
b) Hydrogen
c) Diesel
d) LPG
LPG is predominantly the mixture of Propane and ___

a) Methane
6.
d) ash
Which of these fuels has the highest heating value?

a) Methane
5.
c) hydrogen
Which of the following requires the least amount of oxygen /kg

combustion
a) Carbon
4.
b) sulphur
With increase in the percentage of excess air for combustion of coal, percentage of
CO2 in flue gas.
a) increases
3.
Marks: 50 x 1 = 50
b) Ethane
c) Butane
d) Isopropane
Natural gas consists of mainly the following

a) Ethane
b) Methane
_________________________
Bureau of Energy Efficiency
c) Propane
d) Butane
7.
F & A (from and at) rating of the boiler is the amount of steam generated from
a) water at 0C to saturated steam at 100C
b) water at feed water temperature to saturated steam at 100C
c) water at ambient to saturated steam at 100C
d) water at 100C to saturated steam at 100C
8.
The minimum capacity of any closed vessel which generates steam under pressure
as per Indian Boilers Regulation Act is
a) 2.275 litres
9.
b) conductivity
c) pH
b) low pressure oil burner

d) high pressure oil burner
b) 6032 kg/hr
b) salts
c) carbon dioxide
b) removal of silica
d) phosphate treatment of feed water
b) 540 kcal
c) zero
b) removal of dirt
d) effective removal of line condensate
The purpose of atomisation in an oil fired burner is to

a) increase excess air
c) reduce power consumption
17.
b) increase the surface area of oil

d) reduce the flue gas temperature
The difference in temperature between steam and condensate is the principle of

operation in a
a) thermodynamic trap
c) orifice type trap
18.
Drain pockets are provided in a steam line for

a) effective removal of steam
c) checking of steam line
16.
d) chlorine
Latent heat of steam at the critical point is

a) infinite
15.
d) 1768 kg/hr
De-aeration of boiler feed water is referred to as

a) removal of dissolved gases
c) removal of scales
14.
c) 4089 kg/hr
Demineralization of water is the process to remove the dissolved

a) oxygen
13.
d) conductivity and pH
A boiler generates 8 TPH of steam at an efficiency of 75 %. The enthalpy added to

steam in the boiler is 580 Kcal/kg. The fuel flow rate with a GCV of 3500 kcal/kg is
a) 1452 kg/hr
12.
d) 22.75 litres
The lowest excess air is required in a

a) coal burner
c) high pressure gas burner
11.
c) 227.5 litres
Automatic blowdown controls for boilers work by sensing

a) TDS
10.
b) 22.75 kilo litres
b) thermostatic trap
d) temperature trap
Which of the following benefits is not achieved by maximizing condensate recovery?

a) maximization of boiler output
c) reduction in energy input costs
_________________________
b) reduction in water treatment costs

d) minimization of exit flue gas temperature
19.
Which of the following will be ideal for heat transfer in a heat exchanger
a) super heated steam
c) wet steam
20.
What is the primary mode of heat transfer in an oil fired melting furnaces
a) convection
21.
b) radiation
c) conduction
d) pulsation
Radiation recuperators are used when the furnace flue gas temperature is more than
a) 800C
22.
b) saturated dry steam

d) hot water
b) 600C
c) 400C
d) 200C
Operating the boiler at a pressure less than 80% of the rated pressure will result in
a) lower boiler exit flue gas temperature
b) reduced boiler feed water pump power
c) increased carryover of water
d) all of the above
23.
Amount of oxygen required to burn one kg of hydrogen is

a) 9
24.
b) 8
b) decreases
d) sometimes increases and sometimes decreases
Scale losses in reheating furnaces will

a) increase with excess air
c) have no relation with excess air
26.
b) decrease with excess air

d) increase with CO in combustion gases
Steam trap is a device which discharges

a) steam only
c) condensate only
27.
b) convective heat transfer coefficient

d) radiation factor
If the pressure of saturated steam is reduced through a pressure reducing valve

a) it will get superheated
c) it will produce wet steam
29.
b) enthalpy will reduce

d) enthalpy of evaporation will reduce
Alumina is a ____ type of refractory

a) acid
30.
b) air and incondensable gases only

d) air, incondensable gases and condensate
Ceramic coating in furnaces influences

a) conductivity
c) emissivity
28.
d) 3
The emissivity of conventional refractory ____ with the increase in temperature

a) increases
c) remains the same
25.
c) 0.5
b) basic
c) neutral
The effect of thermal conductivity on thermal resistance of an insulation

a) increases with increased thermal conductivity
b) decreases with decreased thermal conductivity
c) increases with decreased thermal conductivity
d) decreases with increased thermal conductivity
_________________________
31.
If the furnace temperature is T (oK) and the area of opening is A, quantity of radiation
loss in a reheating furnace is directly proportional to
a) T
32.
b) A4
c) A2
The insulating material made by blending and melting of alumina and silica at a
temperature of 1800-2000oC is known as
a) insulating brick
c) fire brick
33.
b) high alumina brick

d) ceramic fibre
In a CFBC boiler ____ are required to capture recycled large amount of bed material
a) settling chambers
c) bag filters
34.
b) mechanical cyclones
d) scrubbers
Electrical energy consumption for coal sizing will be maximum for

a) stoker fired boiler
c) CFBC boiler
35.
d) T4
b) AFBC boiler
d) pulverised coal boiler
For even distribution of fluidized air in AFBC boilers, which one of the following is
used?
a) perforated metal distributor plate
c) compressed air through nozzles
36.
Which material is used to control SO2 emissions in FBC boilers

a) CaO
37.
b) NOx
b) 40%
c) CO2
d) 80%
b) low radiation loss

d) compactness in size
A paper plant needs steam at 3 bar and 10 bar in addition to electric power. The most
suitable cogeneration choice among the following will be
b) back pressure turbine
d) bottoming cycle
The cogeneration system which has high overall system efficiency is

a) back pressure steam turbine
c) extraction condensing steam turbine
42.
d) CO
c) 70%
a) condensing turbine
c) extraction cum back pressure turbine
41.
d) sand
The major advantage of the PFBC boilers are

a) low excess air
c) low hydrogen loss
40.
c) silica
The efficiency of a typical FBC boiler is of the order of

a) 30 %
39.
b) lime stone
The low combustion temperature in FBC Boilers results in minimal formation of

a) SOx
38.
b) secondary air from sides

b) combined cycle
d) reciprocating engine
For standalone gas turbines without heat recovery system, the efficiency will be in the
range of
a) 35 to 40%
_________________________
b) 85 to 90%
c) 75 to 80%
d) 55 to 60%
43.
In a gas turbine, air compressor alone consumes about _____of the energy
generated
a) 20-30%
44.
b) air pre heater
b) heat wheel
d) thermo compressor
Heat transfer by gas radiation in a reheating furnace depends on

b) CO2 concentration
d) all of the above
If pressure of saturated steam increases then

a) enthalpy of steam goes up
c) enthalpy of evaporation goes up
49.
d) heat wheel
Which of the following works on a refrigeration cycle?
a) temperature
c) water vapor concentration
48.
c) boiler
b) reheating furnace
d) gas turbine
a) heat pipe
c) heat pump
47.
d) 50-60%
Recuperator as a waste heat recovery system is used mainly in

a) boiler
c) compressor
46.
c) 40-45%
Which one is the preferred waste heat recovery system in a large gas turbine?
a) economizer
45.
b) 30-40%
b) enthalpy of steam goes down

Which of the following requires the least amount of oxygen /kg for combustion
a) carbon
b) sulphur
c) hydrogen
d) methane
The question is repeat of Question No.3. Award mark if the answer is right.
50.
The amount of carbon dioxide produced by combustion of 1 kg of methane in

comparison to that produced by 1 kg of carbon is
a) more
b) less
c) same
d) data insufficient
-------- End of Section - I ---------
_________________________

Section - II:
SHORT DESCRIPTIVE QUESTIONS
Marks: 10 x 5 = 50
(i) Answer all Ten questions

(ii) Each question carries Five marks
S-1
What is meant by excess air in combustion systems and discuss the

importance of optimum excess air.
o
Excess air is the air provided in excess of stoichiometric air to ensure

complete combustion, since mixing between air and fuel is never perfect
in practice.
If too much excess air were allowed to enter, additional heat would be lost
by heating the surplus air to the chimney temperature. This would result in
increased stack (exhaust) losses.
Too much excess air will reduce flame temperature
Too less excess air would lead to the incomplete combustion and smoke.
High excess level increases the scale losses of the material to be heated
in the furnaces.
S-2
List any five energy conservation opportunities in a boiler system.

1.
Reduce stack temperature
2.
Feed water preheating using economizer
3.
Combustion Air preheating
4.
Control Incomplete combustion
5.
Optimise excess air
6.
Blow down heat recovery
7.
Reduction of scaling and soot losses
8.
Variable speed control of fans, blowers and pumps
9.
Optimising efficiency of boiler by loading the boiler to 65-85% of full

load
10.
Replacement of old and inefficient boiler
11.
Proper coal sizing to minimse unburnt losses
12.
Proper insulation of boiler to minimize surface/radiation losses
_________________________

S-3
What are the disadvantages of direct method of boiler efficiency evaluation

over the indirect method?
Disadvantage of Direct Method
Does not give clues to the operator as to why boiler efficiency of system is
lower or higher
Does not indicate individual losses accountable for various efficiency levels
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
S-4
The efficiency of a boiler on GCV basis is 84%. The fuel contains 0.5 %
moisture and 11 % hydrogen. The GCV of fuel is 10,300 Kcal/kg. What is the
boiler efficiency on the basis of net calorific value?
%age of Hydrogen in fuel
%age of moisture in fuel
NCV = GCV [9 x ------------------------------------ + --------------------------------] 584

100
100
NCV
11
0.5
10300 [ 9 x ----- + -------- ] 584
100
100
10300 [ 9 x 0.11 + 0.005] 584
10300 - 581.08
=
=
9718.92
9719 Kcal / Kg
Boiler efficiency on NCV
S-5
84
------ x 10300
9719
89.02 %
89%
List any five heat losses occurring in a furnace.
_________________________

1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
S-6
Sensible heat loss in flue gas

Loss due to evaporation of moisture present in fuel
Loss due to evaporation of water formed due to hydrogen in fuel
Heat loss due to openings
Heat loss through skin
Heat storage loss
Loss of furnace gases around charging door and opening
Heat loss by incomplete combustion
Loss of heat by conduction through hearth
Loss due to formation of scales
A boiler generates steam at the rate of 12 ton/hr consuming 2 ton/ hr of coal

having 4500 kcal/kg calorific value. Calculate the evaporation ratio and
efficiency of the boiler if the enthalpy of the generated steam is 722.5 kcal/kg
and feed water temperature is 55C.
1. Evaporation Ratio means Kilogram of steam generated per Kilogram of
fuel consumed
12
Evaporation Ratio = --- = 6
2
2. Efficiency of the boiler
12 ton x 1000 Kg / ton x (722.5 55)
=
----------------------------------------------------------- x 100
2 ton x 1000 Kg / ton x 4500 Kcal / Kg
S-7
89 %
200 kg/hr of hot condensate from a heat exchanger is coming out at 6 bar (g)
with a sensible heat of 166 kcal/kg. Using a flash vessel, the condensate is
flashed to 1 bar (g) with a sensible heat of 120 kcal/kg and latent heat of 526
kcal/kg. Find out the flash steam generation in kg/hr.
Flash steam available %
S 1 - S2
----------- x 100
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
S-8
166 - 120
( --------------) x 200 kg/hr
526
17.49 Kg/hr.
What is the principle of CFBC (circulating fluidized bed combustion) boiler?
Evenly distributed air is passed upward through a finely divided bed of

sand . As air velocity is gradually increased fluidisation takes place.
At high fluidizing gas velocities a fast recycling bed of fine material is

superimposed on a bubbling bed of larger particles.
The combustion temperature is controlled by rate of recycling of fine

material.
Hot fine material is separated from the flue gas by a cyclone and is
partially cooled in a separate low velocity fluidized bed heat exchanger,
where the heat is given up to the steam.
The cooler fine material is then recycled to the dense bed.
6 12 mm size fuel and limestone are injected in to the furnace.
While combustion takes place at 840 900 Deg. C., the fine particles
(<450 microns) are elutriated out of the furnaces with flue gas velocity of
4-6 m/s.
S-9
What is heat-to-power ratio of cogeneration system and state its importance?

It is defined as the ratio of thermal energy to electricity required by the energy
consuming facility.
It can be expressed in different units KWth / KWe,
Kcal/Kwh, Bth/Kwh, lb/hr/kw.

Heat-to-power ratio is one of the most important technical parameters
influencing the selection of the type of co-generation system.
The heat to power ratio of a facility should match the characteristic of the cogeneration system to be installed.
_________________________

S-10
Describe in brief the principle of working of heat pipes.
The heat pipe comprises of three elements, a sealed container, capillary

wick structure and a working fluid.
Thermal energy applied to the external surface of the heat pipe causes the
working fluid near the surface to evaporate instantaneously.
Vapour thus formed absorbs the latent heat of vapourisation and this part
of the heat pipe becomes an evaporator region.
The vapour then travels to the other end of the pipe where the thermal
energy is removed causing the vapour to condense in to liquid again,
thereby giving up the latent heat of condensation.
The condensed liquid then flows back to the evaporated region.
Heat pipe can transfer upto 100 times more thermal energy than copper.
-------- End of Section - II ---------
_________________________
10

Section - III: LONG DESCRIPTIVE QUESTIONS
Marks: 5 x 10 = 50
(i) Answer all Five questions

(ii) Each question carries Ten marks
L-1
A chemical plant has an AFBC boiler with the following specifications:
Boiler capacity
: 70 TPH
Boiler pressure
: 60 kg/cm2
Steam temperature
: 500oC
Fuel fired
: coal with 35% ash content
GCV of coal
: 4000 kcal/kg
Theoretical air for combustion
: 5.6 kg/kg of coal
Hydrogen in fuel
: 4%
Specific heat of flue gas
: 0.24 kcal/kgoC
Specific heat of superheated water vapor in the flue gas : 0.45 kcal/kgoC
Operating parameters are given below
(i)
Flue gas exhaust temperature

Excess air
Feed water temperature
Radiation and other losses
Ambient temperature
: 160oC
: 30%
: 105oC
: 8%
: 30oC
Calculate the Boiler Efficiency using indirect method on GCV basis.
If the feed water temperature is 105oC and the steam is produced at 60 kg/
cm2 & 500oC, what is the hourly coal consumption? Total heat of steam at 60
2
kg/ cm & 500oC is 817 kcal/kg.
(ii)
Theoretical air requirement
5.6 Kg / Kg of coal
Excess Air
30%
Actual mass of Air supplied
EA
[ 1 + ----- ] x Theoretical Air
100
30
[ 1 + ---- ] x 5.6
100
7.28 Kg of Air / Kg of coal
m x Cp x (Tf - Ta)
------------------------- x 100
GCV of fuel
a)
Dry flue gas loss
_________________________
11

Total mass of flue gas (m)
% Dry flue gas loss
b)
Mass of actual air supplied +

Mass of fuel supplied
7.28 + 1
8.28
8.28 x 0.24 x (160 30)

-------------------------------- x 100
4000
6.4584
6.46 %
Heat loss due to evaporation of water formed due to H2 in fuel
9 x H2 x [584 + Cp (Tf Ta)]

---------------------------------------------------GCV of fuel
Where H2 Percentage of H2 in fuel
c)
d)
9 x 4 x [ 584 + 0.45 (160 30) ]

-------------------------------------------4000
5.7825
5.78%
Radiation of other losses
8%
Boiler efficiency
100 (6.46 + 5.78 + 8)
79.76%
Hourly Coal Consumption

=
70 x 1000 x (817 105)

--------------------------------0.7976 x 4000
15621.86 Kg / hr
15.621 Ton / hr.
L-2 (a) Briefly explain why the slight positive draft pressure should be maintained in
the furnaces.
(b) Explain the significance of achieving optimum capacity utilisation in furnaces.
_________________________
12
a) By maintaining slight positive pressure, air infiltration in the furnace through

openings and cracks is avoided.
Air infiltration results in
b)
higher heat loss due to high excess air
Lowering of the flame and furnace temperature
disturbance of the air fuel ratio control
cold metal and non-uniform metal temperature
increased power consumption of ID fan
increased scale losses
The significance of achieving optimum capacity utilisation in furnaces is to

minimize the proportionate fixed and variable energy losses. This will lead to
reduced specific energy consumption.
If the furnace is underloaded only a smaller fraction of the available heat in the
working chamber will be taken up by the load and leading to higher variable
losses and therefore efficiency will be low.
Fixed losses in the furnace is significant. Lower loading leads to increase in
fixed losses per unit of product.
So optimal loading will result in minimum losses and maximize the efficiency.
L-3
Discuss in detail four major energy conservation opportunities in steam

systems.
1.
Monitoring Steam Traps
Condensate Discharge
-
Inverted bucket and the thermodynamic disc traps should have

intermittent condensate discharge
Flout & thermostatic traps should have a continuous condensate

discharge
Thermostatic traps can have either continuous or intermittent

discharge depending upon the load
_________________________
13

If inverted bucket traps are used for extremely small loads, it will
have continuous condensate discharge.

Flash Steam
-
If steam blows out continuously in a blue stream, it is leaking steam
If a steam floats out intermittently in a whitish cloud, it is flash

steam
2.
Continuous steam blow and no flow indicate, there is a problem in the

trap
Wherever a trap fails to operate and the reasons are not readily
apparent, the discharge from the trap should be observed.
3.
Avoiding Steam Leakage

Steam leakage is a visible indicator of waste and must be avoided.
Steam leaks on a high pressure mains are prohibited, costlier than an
low pressure mains. Any steam leakage must be quickly attended to.
4.
Providing Dry Steam for Process

Wet steam reduces total heat in the steam. Also water forms a wet film
on heat transfer and overloads traps and condensate equipment.
Superheated steam is not desirable for process heating because it
gives up heat at a rate slower than the condensation heat transfer of
saturated steam.
5.
6.
Utilising Steam at the Lowest Acceptable pressure for the process
The latent heat in steam reduces as the steam pressure increases
But lower the steam pressure, the lower will be its temperature.
Therefore, there is a limit to the reduction of steam pressure.
Proper Utilisation of Directly Injected Steam

The injected steam should be condensed completely as the bubbles
rise through the liquid. This is possible only if the inlet steam pressure
are kept very low around 0.5 Kg/Sq.Cm. and certainly not exceeding
1 Kg/Sq.Cm. If pressure are high, the velocity of the steam bubbles will
also be high and they will not get sufficient time condense before they
reach the surface.
_________________________
14
7.
Miminising Heat Transfer Barrier

Heat is transferred from the steam to the material being heated through
an intermediate heating surface which acts as a barrier between the
steam and the material being heated
In case of indirect heating, temperature difference is required to
overcome the resistance of the barrier between the steam and the
material. It is not just the thermal conductivity of the barrier, along side
the heat transfer barrier in an air film as well as scaling on the steam
side and scaling as well as a stagnation product film on the product
side. The barrier which are formed that inspired the flow of heat from
steam to the material. It has been estimated that air is 1500 times
more resistance to heat transfer than steel and to be removed.
8.
Proper Air Venting

Adequate air venting provision should be made at appropriate position
in the pipe lines, to purge out air as quickly as possible from the
equipment.
9.
Condensate Recovery
For every 6 deg. C. rise in the feed water temperature, there will be
approximately 1% saving of fuel in the boiler.
10.
Insulation of steam pipe lines and hot process equipments
11.
Flash Steam Recovery

Flash steam is produced when condensate at a high pressure is
released to a lower pressure. Flash steam from the condensate can be
separated in a equipment called flash vessel.
12.
Reducing the work to be done by steam

When the steam reaches the place where its heat is required, it must
be ensured that the steam has no more work to do than is absolutely
necessary.
Always use the most economical way to removing the bulk of water
from the wet material.
_________________________
Steam can then be used to complete the

15

process. For this reason, hydro extractors, spin dryers, squeeze or
calender rolls, presses etc. are initially used in many drying processes
to remove the mass of water.
L-4
For a backpressure steam turbine with the following operating data, evaluate
the heat to power ratio (kWTH/ kWE) if the turbine and generator efficiencies are
90% and 92% respectively.
Steam inlet conditions to the back
pressure turbine
Steam outlet conditions of the back

pressure turbine
P = 5.52 MPa
T = 538C
h = 3515.3 kJ/kg
Q = 72 MT/hr
Power output =
From the generator
P = 1.10 Mpa
T = 288C
h = 3022.0 kJ/kg
hf = 781.7 kJ/kg
3515.3
72 x 1000 x [ ---------4.187
3022
0.90 x 0.92
- ------- ] x ---------------4.187
860
0.90 x 0.92
72 x 1000 x [ 839.57 721.75] x ---------------860
8167.39 KW
8167 KW
Heat Utilistion of Steam
Heat to power ratio
_________________________
72 x 1000
3022
781.7
------------------- x [ ------ - --------]
860
4.187 4.187
72 x 1000
--------------------- x (721.75 - 186.69)
860
44795.72 KW
44796 KW
44796
----------8167
5.48
16

L-5
The insulation of a steam pipeline is to be upgraded. With the following data

calculate the simple payback period for the insulation upgradation project.
Length of the steam pipeline
100 m
Bare pipe external diameter
100 mm
Heat loss from the pipe with existing

25 mm insulation thickness
2000 kcal/m2hr
Thickness of insulation to be added
25 mm
Heat loss after insulation upgradation
400 Kcal/m2/hr
Boiler efficiency
75%
GCV of coal
4000 kcal/kg
Annual operating hours
8000 hrs
Cost of coal
Rs. 2000/Ton
Investment for insulation upgradation
Rs. 4 lakhs
Ans
Existing heat loss (S1)
2000 Kcal / Sq. M/hr.
Heat loss after insulation

Upgradation (S2)
400 Kcal / Sq. M. / hr
Pipe dimension
100 mm x 100 m length
Surface area existing (A1) =
3.14 x 0.15 x 100 = 47.1m2
Surface are after insulation (A2) = 3.14 x 0.2 x 100 = 62.8 m 2

With additional 25 mm insulation
Total heat loss in existing system(S1 x A1) = 2000 x 47.1
= 94,200 Kcal / hr
Total heat loss in modified system (S2 x A2)
Reduction in heat loss
_________________________
400 x 62.8
25,120 Kcal / hr
94,200 25,120
69,080 Kcal / hr
17

=
69080 x 8000
-------------------0.75 x 4000
1,84,213 Kg
184 Tons
Annual monetary saving
184 x 2000
Payback Period
4 / 3.68
1.087 years
Annual coal saving
= 3.68 Lakhs
13 months
-------- End of Section - III ---------
_________________________
18

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Regn No: _________________

NATIONAL CERTIFICATION EXAMINATION 2006

Energy Efficiency in Thermal Utilities

Timings: 1400-1700 HRS

Max. Marks: 150

Please check that this question paper contains 8 printed pages

Section I: OBJECTIVE TYPE

Answer all 50 questions

Which of the following is not measured in ultimate analysis?

d) none of the above

LPG is predominantly the mixture of Propane and ___

Which of these fuels has the highest heating value?

Which of the following requires the least amount of oxygen /kg

Natural gas consists of mainly the following