Supplimentary Paper 2 - Set B
Supplimentary Paper 2 - Set B
Supplimentary Paper 2 - Set B
Date: 19.09.2015 Timings: 1400-1700 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
_________________________ 1
Bureau of Energy Efficiency
SUPPLIMENTARY Paper 2 Set B
7. Which of the following requires the largest amount of oxygen/kg of substance for
combustion
_________________________ 2
Bureau of Energy Efficiency
SUPPLIMENTARY Paper 2 Set B
_________________________ 3
Bureau of Energy Efficiency
SUPPLIMENTARY Paper 2 Set B
a) 50 b) 44 c) 66 d) 792
34. Enthalpy of evaporation of any vapour at its critical point will be
a) 69.57 b) 4 c) 17.39 d) 16
40. Which of the following has the lowest stoichiometric oxygen demand (kg/kg of fuel)
_________________________ 4
Bureau of Energy Efficiency
SUPPLIMENTARY Paper 2 Set B
(a) Why should LPG cylinders not be stored in basements or cellars? (2.5 marks)
S-1
(b) Why should the stack temperature of furnace oil fired boilers not be maintained below
160-170C ? (2.5 marks)
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.
(2.5 marks)
_________________________ 5
Bureau of Energy Efficiency
SUPPLIMENTARY Paper 2 Set B
(b) For fuels containing sulphur, low temperatures (below 160-170C) 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 in
cool parts of the chimney or stack, air preheater and economiser.
( 2.5 marks)
A steam pipe of 100mm diameter is insulated with mineral wool. As a part of energy saving
S-2
measures, the insulation is upgraded with efficient Calcium silicate insulation. Calculate the
percentage reduction in heat loss as a result of implementation of the above measure given
the following data,
Ans:
Heat loss thru non-insulated pipe = [10 + (Ts Ta) / 20] * (Ts Ta) ]
Ts = Surface temperature
Ta = Ambient temperature
Heat loss thru non-insulated pipe = [10 + (95 25) / 20] * (95 25) ]
= 945 kcal/hr-m2
(2 marks)
Heat los thru insulated pipe = [10 + (55 25) / 20] * (55 25) ]
= 345 kcal/hr-m2
(2 marks)
% Reduction in heat loss = (945 345) / 945
= 63.5 %
(1 mark)
Calculate the electricity consumption in an induction melting furnace from the following melt
S-3
cycle data,
Ans:
Theoretical energy required for melting = 1250 (0.68 x (1650 35) + 270)/3600
_________________________ 6
Bureau of Energy Efficiency
SUPPLIMENTARY Paper 2 Set B
(3 marks)
Actual energy input to the furnace = 475.1 / 0.65
Electricity consumption = 730.9 Kwh/hr or 730.9 kw
(2 marks)
Paddy husk is being used as a combustion fuel in a water tube boiler. The ultimate analysis
S-4
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 Paddy Husk %
Moisture 11.8
Mineral Matter 17.7
Carbon 32.0
Hydrogen 5.0
Nitrogen 0.9
Sulphur 0.1
Oxygen 32.5
Ans
12 + 32 = 44 (32/12) (32x2.67)
2 + 16 = 18 (16/2) (5x8)
32 + 32 = 64 (32/32) (0.1x1)
Nitrogen 0.9 -
Moisture 11.8 -
_________________________ 7
Bureau of Energy Efficiency
SUPPLIMENTARY Paper 2 Set B
(4 marks)
Therefore theoretical quantity of dry air reqd. = 93.04 / 0.23 = 404.5 kg air / 100 kg fuel
Determine the Energy Utilization Factor (EUF) from the following back pressure cogeneration
S-5
plant diagram and data given.
Back Pr.Steam
P =4 kg/cm2
T =170 C Process
Q =11MT/hr
H =650kcal/kg Plant Condensate
At P = 4 kg/cm2
T =170 C
Inlet Steam
P = 42 kg/cm2
T = 410 C
Q = 11 MT/hr
BPT Power
H = 760kcal/kg Alternator 0.7 MW
Solution
Input heat to turbine = 11,000 x 760 = 8360000 Kcal/hr (1 mark)
Useful heat to process Plant = 11,000 x 650-170 = 5280000 Kcal/hr (1 mark)
Useful Electrical output in alternator = 700x860= 602000 Kcal/hr (1 mark)
For combustion of 500 kg/hr of Natural Gas containing 100% Methane, Calculate the
S-6
percentage of CO2 in the flue gas while 20% excess air is supplied.
_________________________ 8
Bureau of Energy Efficiency
SUPPLIMENTARY Paper 2 Set B
Ans:
In a heat exchanger, steam is used to heat 3.0 KL/hr of furnace oil from 30oC to 100oC. The
S-7
specific heat of furnace oil is 0.22 kCal/ kg/ oC and the density of furnace oil is 0.95 gm/cc.
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.8.0/kWh, which type of
heating would be more economical in this particular case? (assume no losses in electrical
and steam heating process)
_________________________ 9
Bureau of Energy Efficiency
SUPPLIMENTARY Paper 2 Set B
In a sugar mill, a process requires 5 000 kg/hr of dry saturated steam at 7 kg/cm 2 (g). For the
S-8
flow velocity not to exceed 25 m/s, determine the pipe diameter size for distribution of steam.
Specific volume at 7 kg/cm2 = 0.24 m3/kg
Ans.
4 Volumetric flowrate
D
Flow velocity
4 0.333
D
25
D 0.130 m or 130 mm
Since the steam velocity must not exceed 25 m/s, the pipe size must be at least 130 mm; the
nearest commercially available size, 150 mm, would be selected.
(3 marks)
_________________________ 10
Bureau of Energy Efficiency
SUPPLIMENTARY Paper 2 Set B
A liquid waste stream has a flow rate of 3.5 kg/s and a temperature of 75o C with a specific heat
L-1
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 2.8 kg/s, its temperature is 12oC 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 50 oC is required, and assuming that there
are no heat loss from the heat losses from the exchanger, determine
iii) Now because the water outlet temperature is above the outlet temperature of the effluent a
counter-flow heat exchanger is required
LMTD = t1 t2
ln ( t1/ t2)
= ((75-50)-(44.6-12)
ln (75-50)/(44.6-12)
= 25-32.4
ln(25/32.4)
LMTD = 28.54oC
(2.5 marks)
_________________________ 11
Bureau of Energy Efficiency
SUPPLIMENTARY Paper 2 Set B
Q = UA (LMTD)
=445816
800 x 28.54
Area =19.5 m2
(2.5 marks)
Oil fired Boiler is generating 100 TPH of steam at 85% efficiency, operating 330 days in a year.
L-2
Management has installed a water treatment plant at Rs 2 Crore investment for reducing the
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%. Temperature of blowdown water is 175C and
boiler feed water temperature is 45C. Calorific value of Fuel oil is 10200 Kcal/kg.
Calculate the payback period if the cost of fuel is Rs.34500 per ton.
Ans:
Blow down % = Feed water TDS * % make up water x 100
(maximum permissible TDS in boiler water Feed water TDS)
_________________________ 12
Bureau of Energy Efficiency
SUPPLIMENTARY Paper 2 Set B
As a part of energy conservation measure, APH (Air Pre-heater) is installed in a fired heater.
L-3
The APH is designed to pre-heat 240 m3/min of combustion air to 250C. Flue gas enters the
APH at 375C. Calculate the flue gas leaving the stack and also determine the improvement in
furnace efficiency after the installation of APH with the following data
Solution:
_________________________ 13
Bureau of Energy Efficiency
SUPPLIMENTARY Paper 2 Set B
a) Find out the efficiency of the furnace oil fired boiler by the direct method in an agro product
L-5
manufacturing plant given the following data:
b) The oil fired boiler was converted to coconut shell firing maintaining the same
steam and feed water parameters.
Solution:
Annual fuel cost of furnace oil fired boiler = 350 x 7200 x 32 = Rs 8,06,40,000 /year
(1 mark)
Annual fuel cost of coconut shell fired boiler = 924.2 x 7200 x 12
= Rs 7,98,50,880/year
(1 mark)
Annual net monetary savings after conversion
_________________________ 14
Bureau of Energy Efficiency
SUPPLIMENTARY Paper 2 Set B
ii) use in plastic factory where chilled water is used to cool injection moulding machines, and
iii) drying applications such as maintaining dry atmosphere in storage and drying
compressed air
(2 marks)
b) In a situation when both the cooling and heating capabilities of the cycle can be used in
combination
( 2 marks)
(2 marks)
Step 1: In the evaporator the heat is extracted to boil the circulating working fluid
Step 2: The evaporated working fluid is compressed in a compressor rising working fluid
temperature and pressure
Step 3: The heat is delivered to the condenser
Step 4: The pressure of the working fluid is reduced in a throttling valve and condensate
returned to the compressor
(4 marks)
_________________________ 15
Bureau of Energy Efficiency