AP BOE-2013 Paper-1 Solution

IBCI (Indian Best Coaching Institute)
AP BOE-2013 Paper-1 Solution

Q.1(a). Which steam is good for process heating saturated or super heated? And
why?
Ans. Dry saturated steam is good for process heating because it does not contain
moisture. The presence of moisture reduces the total heat in the steam. Hence dry
saturated steam is preferred for process heating
Q.1(b). What is super heater starvation? What factors affect the super heater
design in boiler?
Ans. Non establishment of steam flow through super heater tube in a running boiler is
called starvation. Starvation may be because of puffing of drum safety valve prior to
super heater safety valve. Super heater tube will be over heat due to no heat transfer
during starvation.
The factors affect the super heater design in the boiler are as follows:
1. A high steam temperature may be maintained constant over a wide load range
with a convection super heater of reasonable size only by tolerating a high furnace gas
exit temperature.
2. If high furnace exit temperature cannot be tolerated because reduction in control
range of the convection super heater must be accepted.
3. If either a high furnace exit temperature nor a limited control range can be
tolerated it is advisable to use a combination radiant and convection super heater
preferably by twin furnace type of unit with the combination super heater separately find.
4. For regulating steam temperature control of the by pass de superheater or
condenser type may be used for conventional super heater installation units of the twin
furnace type with separately fixed super heater are controlled by differential fixing and
such units can be designed for lower furnaces exit temperature and wider control ranges
than conventional units..
5. Damage to the super heater in operation and during start up may be avoided by
proper care in equalizing gas and steam distribution to the super heater and by proper
manipulation of the fixing equipment and super heater when starting.
Q.1(c) Discuss briefly about chattering and hang up of safety valve?

Ans. Chattering is the rapid opening and closing of a pressure relief safety valve. The
resulting vibration may cause misalignment valve seat damage and if prolonged can
cause mechanical failure of valve internal and associated piping.
Some cause of chattering include excessive inlet pressure drop excessive back
pressure and over sized relief valve and a relief valve which must handle widely carrying
flow rates. We will explain the under normal process conditions the vessel pressure is
below the set pressure of the relief valve/safety valve and the pressure at the safety
valve is same as vessel pressure, the pressure at the safety valve increases by the
same amount and if the pressure exceeds the relief valve set the pressure valve open.
Hang up of safety valve: when the valve does not reset back due to some setting
defect. This is called hang up of safety valve.
Q.1.d How do you find tube leakage in running boiler?

Ans. Through AMS acoustic monitoring system we can find tube leakage in running
boiler through the Doppler effect we can just detect it leakage.
website link: http://mithileshkhudawal.wix.com/boeindia

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Q.2(a) A safety valve is designed to blow of at a guage pressure of 0.8 N/mm2.The
valve is held buy a closed call dad helical spring of mean coil diameter 180 mm
and valve disc diameter is 80mm. Find the diameter of the spring rod if shear
stress of rod is 75 N/mm2?
Solution :
Kindly refer our study material Numerical Q No. 65
Q.2(b) A hollow shaft is to transmit 300 kw at 80 rpm. If the shear stress is not to
exceed 60 N/mm2 and internal diameter is 0.6 of the external diameter. Find the
external and internal diameter assuming the max torque is 1.4 times the mean
torque?
Solution :
Q.3(a) Discuss about procedure for super heater safety valve pressure setting
and drum safety valve pressure setting if the boiler approved working pressure is
105 kg / cm2 and inlet pressure of the steam turbine is 95 kg / cm2?
Ans. Super heater safety valve setting is just in the way that it set off before drum safety
valve. So the super heater safety valve pressure must be lower than 105 kg /vm2.
The pressure setting of the super heater safety valve should be less than that the
designed pressure of the boiler i.e less than that of the drum safety valve to ensure flow
of steam through super heater under blow off conditions. The pressure setting of one
steam drum safety valve should be same as design pressure of the boiler.The pressure
setting of another safety valve should be 2-3 % more than the designed pressure of the
boiler.
Pressure setting of the boiler safety valve :

If it is found that the boiler safety valve is not lifting at the designed lifting pressure
manual pressure setting of the boiler safety valve has to be done for the proper and the
safe operation of the boiler.The adjustment can be carried out on this type of valve to
give the designed discharge and blow down characteristic.
1. Safety valve pressure setting can be done from high to low pressure or vice
verse.
2. Take necessary personal safety valve precaution and arrange tools ie gagging
tool and master gauge.
3. Slowly raise the boiler pressure and blow off the safety valve manually few times
for thermal expansion and to reduce the thermal stress on the valves.
4. The screw down all the safety valve higher than the setting pressure at which you
are going to set.
5. Gain the boiler steam pressure 2- 3 % more than the designed pressure of the
boiler then stop fixing and on screw the first valve safety valve slowly when it blow off at
2- 3 % more than the designed pressure then note this opening and closing pressure of
the valve and finally gag it.
6. Raise the boiler pressure at the designed pressure of thhe boiler and unscrew
the 2nd valve when it blow off at designed pressure than note this opening pressure and
check the closing pressure also.Feed check the setting and gag the valve.
7. Then set the super heater safety valve lower than the designed pressure of the
boiler in same procedure.
8. Finally take out the gagging tools.pressure settign should be done in presence of
surveyor.
Q.3(b) What is stress relieving? How it is useful in boiler maintenance?
Ans. Stress Relieving: - This treatment is similar to tempering and except that, the
parts are cooled slowly inside the furnace. This treatment is given to the parts, which are
cold formed/ work hardened steel materials like pipe bends, swaged pipe ends. It
reduces hardness and improves ductility and toughness.
The ASME welding code is referring to require that each type of weld procedure be
qualified. This mean that it as been tested and approved for the type of weld being
made. There are certain variables such as metal type, metal thickness, size of weld,
weld position etc that are called variables. Some are essential meaning they cannot be
changed and other are non essential which mean that there is some degree of variability
in performing this weld procedure.
It is useful in boiler maintenance because:
1. It realized stress at the weld joint.
2. Thus it can avoid destruction of the metal when metal exposed or contract.
Q.4(a) What is boiling mechanism ?what are types of boiling?

Ans. Boiling mechanism: Remember that an express a machine facilitate to basic
function to make express and to steam. The different boiling mechanism determine how
efficiently it can do these two action.express brewing temperature should be around
more temperature.
Generally in boiler mechanism there are two type of boiling mechanism:
1. Nucleate boiling: it is formation and release of steam bubbles at the tube
surfaces with water still wetting the surface immediately.since the tube temperature at
surface is closer to saturation temperature the tube is always safe against failure.
2. Film boiling: Film boiling is the formation of steam film at the tube surface in
which the metal temperature rise sharply.this lead to instantaneous or long term over
heating of tubes and failures.film bolling begins due to high heat flow or low velocity or
inclined tubes.
3. Transition boiling: Transition boiling is a stage in between nucleate and film
boiling having features of both of these stages.
Q.4(b) Discuss about nucleate boiling in detail with sketch?

Ans. Nucleate boiling: When vigorous combustion is taking place, high heat flux is
generated in the radiant zone of the furnace. As heat flux increases, the water wall tubes
get more heat and the temperature of the metal surface tends to increase fast. But the
film layer of water adjacent to the inner wall of the tube receives the heat and the water
temperature near the surface starts increasing. The temperature of the water at this
location reaches saturation point. At this point the transformation from liquid to vapour
stage occurs locally at the layer of water adjacent to the tube inner wall. Since bulk of
water inside the tube at subsequent layers does not reach the same level of temperature
to reach saturation point.
The water vapour near the inner wall of the tubes bubble out and travel towards
core of the water flow in the tube. As soon as the bubbles enter the inner core, the
stream of water, which has not yet reached saturation temperature, receives the heat
from the bubbles of vapour. The vapour bubbles collapse giving away their latent heat to
raise the temperature of water. As long as this process of bubbling close to inner metal
surface and collapsing when it travels towards core of the water, tube metal is kept
under safe temperature limit, the condition is known as ‘Nucleate Boiling’. Nucleate
boiling regimes are characterized by high heat transfer coefficients.

Q.5(a) What is attemperation and discuss about it purposes?

Ans. Attemperation is the process in which water is prayed to control the temperature.
In this case feed water from the boiler feed pump is sprayed directly to the steam coming
out from the primary super heater through the nozzle. Here the temperature of steam
reduces, This steam then passes through the secondary super heater. If outlet
temperature of the super heater is high than the control valve allow more spray water
through the nozzle to reduce temperature. The Temperature control valve is put in auto
mode so that the spray water quantity can be adjusted automatically.

Q.5(b) A boiler is operating at 100 bar ad 535 degree centigrade with steam flow
rate is 105 tph , the super heater temperature maintained by 2 stage attemperation.
Attemperation feed water supplied at 156 degree centigrade and super heated
steam temperature of the second stage is to be maintained at 490 degree
centigrade to maintain the main steam temperature. The first stage attemperator
inlet steam temperature is 515 degree centigrade. Find the attemperation water
flow in the first stage attemperation to maintain the outlet at 490 degree
centigrade.( inlet steam enthalpy spray water enthalpy and outlet steam enthalpy
are 3413.63 kj/kg. 658.12 kj/kg and 3349.18 kj/kg respectively?
Solution :
Q.6(a) What is difference between CFBC BOILER and PFBC (Pressurised

Fluidized bed combustion) boiler?
Ans. CFBC BOILER is capable of burning fuel with volatile content as low as 8 to 9 with
low ash melting temperature such as sood and biomass have been proved due to feed
stocks in CFBC due to low temperature of 850 degree centigrade go 900 degree
centigrade. CFBC boiler is not enough to bound by the tight restrictions on ash contents
either it can be affectively burn fuels with ash content up to 70% fuels with ash content.
CFBC system components
1. Fluidized bed combustor and associated system.
2. Fluidized bad heat exchanger.
3. Solids separation system recycling cyclone u beam particles separator.
4. Conventional Steam turbine system.
5. Fuel preparation and feeding system.
6.Ash removal system.
PFBC BOILER is a new type of Fluidized bed design the processing bed was developed
in the late eighties to further improve the efficiency level in coal fitted power plants.
PFBC plants are smaller in size than the CFBC plants temperature.PFBC system
comprises of following system.
1. Boiler and associated system.
2. Conventional steam turbine system.
3. Gas turbine.
4. Hot gas cleaning system.
5. Fuel preparation and feeding system.
6.Ash removal system.
Q.6(b) What are all the provision given in CFBC boiler to maintain the bed
temperature with the range of 800 to 950 degree centigrade. ?
Ans. There are following provision are made to maintain bed temperature between 800
to 950*C.
1. The air flow adjustment vale is for regulation of aeration to help in proper start up or it
will take more time to establish the lips seal.
2. Air flow meter after APH ensures the leakage air flow in APH is ignored. Moreover
tube leakage is identifiable in case the damper opening in reduces for the same air flow.
3. Pressures to ensure penetration is possible for copper reduction is possible by
choosing to close the damper.
Q.6© Explain about natural circulation and forced circulation in detail?
Ans.
Natural circulation :
In a natural circulation boiler the circulation is achieve by the difference in the density
when the water in boiler is heated. In natural circulation the steam boiler the circulation
of water is by connection current. Which are set up during the heating of water. In most
of the boiler there is natural circulation of water the fundamental principal of which is
based on the principal of thermo siphon.
Forced circulation : In this extra pump is required to increase the circulation rate as
compared to that of natural circulation.
Q.7(a) What ate the safety precaution to be taken before entering to boiler
maintenance work?
Ans.
1. Before starting any maintenance work safety work permits has to be taken from
authorities.
2. Ensure 24 V DC supply for illumination purpose into the boiler.
3. Always use suitable PPEs(Personnel protective equipments).
4. Ensure proper drainage of steam & water from boiler.
5. Skilled workman should be deputed for work.
6. Ensure proper ventilation in sophisticated space.
7. Pressure vessel maintenance work should be done after approval of IBR
authorities.
8. Supervisor should be available all time at work.
9. If work at height then height permit should be taken.
10. Arrangements of fire extinguisher should available at workplace.

Q.7(b) A boiler working on 100 kg/cm2, 530' c steam flow is 95 TPH.The
economiser inlet water temperature is 210'c.Find the coal flow in tonnes per hour
when the boiler efficiency is 87% and fuel GCV is 3200 kcal/kg. (Steam enthalpy
and water enthalpy are 3464.33 kj/kg and 897.631 kj/kg respectively.?
Solution :
Q.8(a) Explain the difference between surface condenser and air cooled
condenser?
Ans :
SN Parameter Surface Condenser Air cooled condenser

1 Cooling fluid media Water Air
2 Installation cost Medium High
3 Specific water High (usually Low (usually
consumption 4.5Tonnes/Mwh) 0.5Tonnes/Mwh)
4 Efficiency Very Good Good(depending upon
ambient temp
5 Aux power Very high Less w.r.t. surface
consumption condenser
6 Water Treatment Water treatment required No need of water
treatment
7 Condensate Hot well is enough CST(Condensate storage
storage tank required
8 Periodic cleaning Basin cleaning can be Usually weekly panel fins
done during plant cleaning system required
shutdown along with annual chemical
cleaning
9 Area required Less More
10 Impact of dusty Nomination impact Panel fins may get
environment chocked which is reducing
condenser performance
Q.8(b) What are the factors that affect the condenser size?
Ans. The factors that affect the condenser size are as follows:
1. Cooling media
2. Ambient condition (temp & humidity)
3. Type of condenser
4. Approach
5. Range
6. Heat load
7. COP (Coefficient of performance).
8. Vacuum (Exhaust steam pressure).
9. Cooling tubes/bundle type
10. TTD(Terminal temperature difference)
Q.8© How do you find leakage in condenser? How condenser leakage affects
power plant performances?

Ans. The use of various tracer in testing for locating the Condenser leakage has
widely accepted practice. Several different tracers include a halogen atex such as helium
and perfluro carbon have been investigated since the invitation use of such tracers for
par plants leak detection more than 10 years ago. Helium and helium mass
spectrometers have been the most widely used means of testing.
Condenser leak has the following impact on power plant performance:

1. Increases loading on air extraction system(i.e. Hogger/Ejector etc.)
2. Increases +ve pressure on turbine exhaust.
3. Increases specific steam consumption.
4. Increases turbine & plant heat rate.
5. Increases heat load on cooling tower(required higher cooling water flow).
6. Increases auxiliary power consumption.
Q.9 answer any four of the following.?

(a) Define Boiler as per the Boiler Act 1923.
(b) Super critical boiler.
© Calculate the weight of coal in tones which is stored in a conical shape in the
yard if the diameter at base and height are 100mts and 75mts respectively.
Assume density of coal is 0.9 kg/m3.
(d) How do you prevent Boiler feed pump from vacuum lock and cavitations?
(e) Furnace explosion.
(f) Corona effect in ESP.
(g) Advantages and disadvantages of using Bagasse as fuel.
Answer :
(A) Definition of boiler as per the boiler act 1923.
As per the Indian Boiler Act & Regulations (IBR)1923, a boiler may be defined as a
closed vessel with a capacity of 22.75 liters or more in which water is converted into
steam for external use, under pressurized condition. The term ‘boiler’ includes all such
mountings fitted to the vessel, which remain wholly or partly under pressure when steam
is shut off.
(B)Super critical boiler:
Two factors, namely the necessity to reduce emission of CO2 (Green House Gas) and
ever increasing cost of fuel have always attracted the attention of the designer. In order
to achieve these two objectives, the designers have taken steps to increase the thermal
efficiency & power cycle by adopting the usage of Super Critical Pressure steam. A
super critical boiler is one, which operates above the critical steam pressure of 229
kg/cm2(g) at 374*C. At this critical pressure, steam and water are at the same density,
which means steam, is as compressed as water and at a temperature of 374*C, water
can does not require any latent heat to become vapour from fluid. When such substance
is heated above the critical temperature, dry superheated steam is produced, which is
very suitable for driving turbo generators. In super critical boiler, are provided with only
pre-heater and super heaters and there is no boiler drum. Also, the super critical
pressure boilers are of once through, forced circulation type.
(C)Solution:
Volume of conical shaped coal
V =(base area × perpendicular height )/3
={(3.14X50x50)x75}/3 =196250 m3
Weight of coal “w” = Volume of conical shaped coal X Density of coal
=196250x.09 =176625 Kg =176.625 Tonnes Ans.

(D) Prevention of Boiler feed pump vacuum lock & cavitations:
During suction of the Boiler feed pump(BFP), some of the saturated feed water may
flash into vapour due to reduction in pressure causing vapour lock and cavitations
problems in the pump. To prevent this from occurring the deaerator is located at a
sufficient height (H) from the basement where the pump is installed so that the pressure
before suction is (Psat + ρfgH). When this water is sucked by the pump, the pressure
does not fall below Psat and there is no flashing of any water into vapour, which protects
the BFP from any damage due to vapour lock and cavitations.
( E ) Furnace explosion:
Numerous conditions can arise in connection with the operation of a boiler that
produces explosive conditions. The most common of these are as follows.
a) An interruption of the fuel or air supply or ignition energy to the burners, sufficient to
result in momentary loss of flames, followed by restoration and delay re-ignition of an
accumulation.
b) Fuel leakage in to an idle furnace and the ignition of the accumulation by a spare or
other source of ignition.
c) Repeated unsuccessful attempts to light off without appropriate purging, resulting in
the accumulation of an explosive mixture.
d) The accumulation of an explosive mixture of fuel and air as a result of flame is at one
or more burners in the presence of other burners, operating normally or during lighting of
additional burners.
e) The accumulation of an explosive mixture of fuel and air as a result of a complete
furnace flame out and the ignition of the accumulation by a spark or other ignition
source, such as could occur where attempting to light a burner(s).
f) Purging with an airflow that is too high, which stirs up combustibles smouldering in
hoppers.
(f) Corona effect in ESP:

WHEN THE HIGH DC NEGATIVE POTENTIAL, APPLIED TO THE DISCHARGE
ELCTRODE W.R.T. THE GROUNDED COLLECTING ELECTRODE, IS INCREASED,
AT A PARTICULAR VOLTAGE THE BREAKDOWN OF THE MEDIUM TAKES PLACE,
RESULTING IN THE DISCHARGE OF FREE ELECTRONS FROM THE DISCHARGE
ELECTRODES. THIS PHENOMENON IS KNOWN AS ‘CORONA DISCHARGE’.
The Maximum amount value of the voltage drop that a layer of cement dust can support
without break down is defined by its di-electric strength. This value is typically in the
order of 15-20KV. When this value is exceeded, either the formation of Back corona or
the propagation of spark across the entire electrode space results in.
(g) Baggasse: Baggasse is the refuse of sugarcane from which the juice is extracted in
sugar mills. Bagasse is bulky tenacious and fibrous. Bagasse contains 30 to 50% wood
fibre, 01 to 10% sucrose, & 40 to 60% moisture. The C.V. of Bagasse with 54% moisture
is about 2222 kcal/kg. For better burning, preheated air (at 204°C) is used.
Advantages :
1. Low cost fuel.
2. Eco friendly fuel no negative impact on environment.
3. Less ash content.
Disadvantages :
1. Water stray will be during storage.
2. Lower GCV fuel.
3. Smell during storage.

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AP BOE-2013 Paper-1 Solution

Q.1(c) Discuss briefly about chattering and hang up of safety valve?

Q.1.d How do you find tube leakage in running boiler?

website link: http://mithileshkhudawal.wix.com/boeindia

Pressure setting of the boiler safety valve :

Q.4(a) What is boiling mechanism ?what are types of boiling?

Q.4(b) Discuss about nucleate boiling in detail with sketch?

website link: http://mithileshkhudawal.wix.com/boeindia

Q.5(a) What is attemperation and discuss about it purposes?

website link: http://mithileshkhudawal.wix.com/boeindia

Q.6(a) What is difference between CFBC BOILER and PFBC (Pressurised

website link: http://mithileshkhudawal.wix.com/boeindia

SN Parameter Surface Condenser Air cooled condenser

website link: http://mithileshkhudawal.wix.com/boeindia

Condenser leak has the following impact on power plant performance:

Q.9 answer any four of the following.?

website link: http://mithileshkhudawal.wix.com/boeindia

(f) Corona effect in ESP:

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