Paper 2 Pink 22-4 NATIONAL CERTIFICATION EXAMINATION FOR ENERGY MANAGERS & ENERGY AUDITORS - JULY, 2022 PAPER - 2: ENERGY EFFICIENCY IN THERMAL UTILITIES Date : 30.07.2022 Timings : 14:00-17:00 HRS Duration: 3HRS Max. Marks : 150 Section -I: OBJECTIVE TYPE Marks: 50 x 1 = 50 1, | Which of the following is correct for ‘Viscosity’. a). Increases with temperature b) Increase with pressure and temperature ©) Decreases with temperature )_None of the above 2. | ‘Specific Heat’ is measured with which unit. a) Keal/kg b) kcal*c ©) Kg/cubie meter d)_None of the above 3. | How much Energy is released from burning of 1 kg Hydrogen. a) 28922 Keal/Kg b) 36200 Kcal/kg, ©) 8084 Keal/Kg d)_2225 Keal/ke 4. | How much air is required for burning of 3 kg of Carbon in fuel. a) 8.0kg b) 34.7 kg ©) 3.6kg. d)_47.8 ke 5. | Which of the following refers to External Water Treatment Methods. a) lon Exchange Process b) De-aeration ¢) Reverse Osmosis d)_Allof the above 6. | Which of the following is correct related to critical point of water? a) 221.2 bar absolute pressure and 374.18 Deg C b) Latent heat is zero. €) Super critical boilers operate above critical conditions d)_Allofthe above 7. | With increase in steam pressure, which of the following is correct for ‘Latent Heat’ of water. a) Latent heat decreases b) Sensible heat decreases ©) Boiling point decreases, d)_Total enthalpy decreases 8, | If hris 159 kcal/Kg, hr, is 498 kcal/kg , what will be total heat of steam with 5% Moisture, a) 649 Keal/Ke b) 632 Keal/kg ©) 657 Keal/kg. d)_624 Kcal/KeWhich of the following is function of steam trap a). To discharge condensate as soon as it is formed, b) Not toallow steam to escape ©) To discharge air and other non-condensable gases d)_Allof the above. 10. Which of the following trap is suited for steam tracing applications. a) Inverted Bucket trap b) Ball Float trap ©) Thermostatic trap. d) Thermodynamic trap. i. Recuperators are used for . a) Preheating of combustion air b)_Preheating of Fuel ¢) Preheating of water. d)_Preheating the stock. 12. The wall losses of furnace depends on a) Emissivity of wall b) Thermal conductivity of refractories ©) wall thickness d)_Allof the above B Determination of economic thickness of insulation depends on a) Cost and heat content of fuel 'b) Estimated cost of insulation and hours of operation ©). Boiler efficiency d)_Allof the above 14. The unit of surface heat loss is a) keal/hr m b)keal/hr m? c) kcal/hr Deg C d)_None of the above 15, Electrostatic Precipitators can remove ash upto: a) 60-85 % of fiy ash b) 70-95 %of fiy ash ©) 95-99% of fly ash d)_ 50-80% of fly ash 16. V7. Which of the following boiler will have lowest size for 500 MW generation a) CFBC Boiler b) AFBC Boiler ©) PFBC Boiler d)_None of the above ‘A co-generation system configuration in which heat is utilized and power is produced in next stage a) Combined cycle b) Bottoming Cycle ) Topping Cycle d)_None of the above 18 ‘Simultaneous generation of steam, power and refrigeration refers to: a). Triple point b) Trigeneration ©) Combined cycle generation d)_Bottoming cycle cogeneration19. | For every 15°C rise in feed water temperature of boller will result into overall thermal efficiency improvement by a) 6% b) 1% 0 3% d) 5% 20. | Which of the following is direct contact heat exchanger, a) Reboiler/Kettle b) Heat Pipe ©) Deaerator d)_Heat Pump 21. | Apinch analysis can result in a) Reduction in cooling water b)_ Increase in cooling water ©) reduction in steam d)_botha&e 22. | Regenerators utilizing waste heat are widely used in a. Cement industries b. Steel ©. Glass melting furnace d._ Aluminium 23. | A pulp and paper 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 ¢._Extraction cum back pressure turbine d. Bottoming cycle 24. | Low combustion temperature in FBC boiler results in reduction of a. Sox b. NOx CO, dO, 25. | An increase in bulk density of refractory increases its a. Volume stability b. Heat capacity c._ Resistance to slag penetration d. Allof the above 26. | The efficiency of a reheating furnace, operating at 10 tonnes per hour consuming furnace oil of 230 kg/hour for reheating the material from 40 “C-1100 °C (consider specific heat of material is 0.13 kcal/kg “Cand calorific value of furnace oil is 10000 kcal/kg) is, a. 55 b. 60 65 d._70 27. | The devise that upgrades a low temperature heat source to a high temperature sink is called a. Heat pipe b. Heat pump . Plate heat exchanger 4, economiser 28. | The difference 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 ¢. High heat capacity d,_ Thermal shock resistant 30. Furnace wall heat loss does not depend on a. Temperature of external wall surfaces b. Velocity of air around the furnace ¢. Temperature of combustion air d. None of the above31. Which among the following is most viscous fluid? 2. DO b. Kerosene c. HS0 d. Furnace oil 32, | Hot condensate at 4 bar g pressure has heat content of about 600 ki7kg, when it released to atmospheric pressure (0 bar g), each kilogram of water can only retain about 419 k! of heat, The latent heat of flash steam is 2134 kl/kg, then percentage (%) flash steam available will be a. 11.48% b. 12.48% c. 8.48% dd. 14.48 % 33 | Correction factor for LMTD is applicable for a. Counter current b. Parallel flow c. Cross flow d. Both a & b 34. | ich one i Which one is the preferred waste heat recovery system in large gas turbine? a. Economiser b, Air pre heater c. HRSG d. Heat wheel 35. i ‘An axial compressor is used in conjunction with which of the following a. Back pressure steam turbine b. Gas turbine . Condensing turbine d. Extraction cum condensing turbine 36. Pick up the wrong statement: The thermal efficiency of the furnace increases by 2. Increasing the furnace loading b, Increasing the excess air flow rate . Reducing the surface heat loss d, Minimizing the CO loss and unburnt losses 37. | pas i i Major heat loss in an oil-ired boiler is accounted by 2. Blowdown loss b. Un-burnt carbon loss . Surface radiation loss d. Stack loss 38. | For complete combustion of every kg of FO firing, the approximate theoretical quantity of air required is: a 12ke b, akg ©. 16kg d. 18kg 38. Select the odd one among the following a. Condenser b. distillation column ©. evaporator d. cooling tower 40. | The equipment having the highest efficiency in case of cogeneration plant is a. Electric generator ». Boiler 1D fan ¢. Steam or gas turbine d. Boiler 41 Oxygen percentage (by volume) can be measured in flue gas by using a. Ultrasonic tester b. Potassium oxide probe ©. Copper tubes 4, Zirconium oxide probe 42. | 1000 kg of water is to be heated from 30 to 70 °C. the heat gained by water will be a, 40000 keal/hr b, 40000 keal . 40000 ks , 40000 ki/hr43. Heat wheels are mostly used in situation of, a. high temperature exhaust gases b. heat exchange between large masses of air having small temperature differences . heat transfer between a liquid and gas d. corrosive gases a4, Ina CFBC boiler the capture and recycling of bed materials is accomplished by a. Bag filter b, Settling chamber ¢. Cyclone d. Scrubber system a5, 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 of the following is related with heat pipe. a) Can transfer upto 100 times more thermal energy than copper b)_ Uses 2 pump for moving the working fluid ¢) Consists of several plates in series d)_Allthe above a7, Condensate recovery in steam system a) Improves boiler feed water quality b) Maximizes boiler output ¢) Reduces water consumption d)_Allthe above ‘Across the pressure reducing valve of a steam system a) Output enthalpy decreases b) Steam becomes wet ©) Steam temperature increases d)_Enthalpy remains the same 49, The fiash 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 ©) medium d)_None of the above 50. Unit of heat to power ratio is a) kwh/kcal b) kcal/kwh ©) kwh/btu d)_Allthe above . End of Section -Section - II: SHORT DESCRIPTIVE QUESTIONS Marks: 8 x 5 = 40 S-1_| The ultimate analysis of Indonesian coal is as given below: Carbon : 59%, Hydrogen: 4%, Sulphur: 0.56%, Mineral Matter: 14% Oxygen : 12%, Moisture: 9.43%, Nitrogen: 1.01% Find out actual mass of air supplied for combustion of 2000 kg/hr of coal with 60% excess air 3 Marks b. Find out NCV of the fuel if GCV of the coal is $500 kcal/kg 2 Marks Soin |a) Theoretical air required for complete combustion = [(11.6 x C) + (34.8 x (Ho -Op /8)} + (4.35 x S)]/100 g/kg of fuel [(11.6 x59) + {34.8 x (4 -12/8)} + (4.35 x0.56)]/100 ke/kg of fuel = 7.73 kg of air/kg of fuel Excess air supplied = 60% ‘Actual mass of air supplied 1 + EA/100} x theoretical air 1+60/100} X 7.73 2.37 kg of air/kg of fuel Air supplied for combustion of 2000 kg/hr of coal = (12.37 x 2000)/1000 = 24.74 TPH... 3 marks b) NCV of the fuel ev ICV + 584 x (SH+M) 5500 = NCV + $84 x (9x0.04+0.094) Nev = 5234 keal/kg 2 marks $2_| Name any five parameters required for determination of furnace oil fred reheating furnace efficiency by direct method. Soin Weight of input material ‘Hr Furnace oil consumption litre/ar Specific gravity of oil Final material temperature Deg Initial material temperature Deg C Outlet flue gas temperature Deg C Specific heat of the material Kcal/Kg Deg C GCV of oll Keal/kg 53 _| Milkis evaporated in a steam jacketed kettle of 700 kg capacity as a batch process. Milk is heated from 35 °C to 100 °C, where 35 % of its mass is driven off as vapour. The other data’s are given below: Specific heat of milk is 0.9 kcal/kg °C Latent heat of steam at 1 kg/cm’g is 525 kcal/kg. Ignoring the heat required for heating the kettle, calculate the quantity of steam required per batch. 3 Quantity of Water evaporated from milk = 700 x0.35 Sol = 245 ke/batch Heat required to raise temperature of milk = 700x0.9x(100-35) = 40950 kcal/batch Amount of heat required to evaporate 245 kg of water = 245x540[32300 Keal/Batch Total Heat required 10950+132300 '73250 Kcal/batch Total steam required '73250/525 =330 ke/batch. S4_ | Calculate the heat loss from an uninsulated pipeline of 50 mm diameter of 500 mtr length carrying process liquid. 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. 34 Existing Heat loss (5) {10+(150-32}/20}x(150-32) Sol = 1876.2 kcal/hr-m? 2 marks Modified Heat Loss (S1) = {10+(50-32)/20}x(50-32) 196.2 keal fhm? ae nesnnesninenn marks Reduction in heat loss = mxDxl x(2035-196.2) = 3.14x0.05x 500x(1876.2-196.2) 31946.89 kcal/hr... sn vow Lark $5 | Write short notes on = Each 2.5 Marks 2) Heat wheel b) Heat pump $5 | Heat wheel — Refer Guidebook -2, Page 222 Sol_| Heat pump ~ Refer Guidebook -2, Page 228 $6 | A counter flow heat exchanger using hot process liquid is used to heat water. The flow rate of water is 10 m’/hr. The process liquid enters the heat exchanger at 95 Deg C and leaves at 55 Deg C. The inlet and exit temperatures of water are 30 Deg C and 42 Deg C respectively. The specific heat of water is 4.18 Ki/Ke Deg C. Calculate the heat transfer area, if the overall heat transfer coefficient is 762 W/m? °C. 36 ‘Water flow rate Sol Heat content in water 10x 1000 = 10,000 kgihr 10000 x 4.18 x (42-30) = 10000 x 4.18 x12 01,600 ki/hr (0600/3600 = 139.33 kW Now LMTDer= _28 In[ 2.13) 37,33 °C ‘Area of Heat Exchanger = 139.33x1000/ (762x37.33) 139330 /28445.46 89 m? 87 | A coal fired boiler is generating 40TPH 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 89%. 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%. Calculate the fuel saving achieved by reduction in blow-down, if the TDS of feed water is reduced to 300 ppm. 9 (Feet water 05 ppm x Makeup Water), 199 Sol low Down (%) = ol Blow Down *6) = —igzimum Permissible TDS — Feed Water TDS Initial blow down = (500 x 8/100 x 100)/(3000-500) = 1.6 % Improved blow down with TDS of 300 ppm = (300 x 8/100 x 100}/(3000 - 300) 0.88% Reduction in Blow down = 1.6 ~ 0.88 = 0.72% Reduction in blow down quantity = 0.72 x 40 x 1000/ 100 = 288 ke/hr Heat Energy Saving = M x Cp x dT = 288x 1 x (170 75) = 27360 kcal/hr Fuel Oil Saving = 27360 / (5000 x 0.72) = 7.6 kg/hr ‘Annual Fuel Saving = 7.6 x 8000 = 60800 kg/annum = 60.8 MT/annum $8 _| Explain the difference between bottoming and topping cycle with an example, 58 Sol | Refer Guidebook-2, Page no: 194 & 195, End of Section - II Section - III: LONG DESCRIPTIVE QUESTIONS x 10= 60 LI |i) Explain how a FBC boiler works. How is it different from CFBC boiler? 5 Marks ii) List any five properties of refractories. 5 Marks S|) Refer Guidebook -2, Pg 173, 178 & 179 ) Refer Guidebook -2, Pg 156 & 157 v2 Each 2 Marks 1) Explain the working of a direct contact heat exchanger. 2), Explain any two methods of testing of steam traps. 3) What are the benefits and applications of pinch technology in process industry? 4) Uist any two advantages of ceramic fibre. 5) Why slight positive pressure is to be maintained in a reheating furnace?1) Refer Guidebook -2, Pg 230 2), Refer Guidebook -2, Pz 94 to 96 3) Refer Guidebook -2, Pg 252 4) Refer Guidebook -2, Pg 165, 5)_Refer Guidebook -2, Pg 132 3 ‘An 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 Oxygen Nitrogen 36 12 14 Sulphur 36 Moisture 14 GCV of Petcoke Onin flue gas Flue gas temperature Heat loss due to radiation & convection Loss due to unburnt in fly ash & bottom ash Specific heat of flue gas Specific heat of water vapour Ambient Temperature Humidity in ambient air Steam generation at 110 barg & 520°C Steam enthalpy at generation pressure and temp Feed water temperature Steam drum pressure 8430 keal/ke 26% 2250°C 1% 0.5% 0.29 keal/kg °C 0.45 kcal/kg °C 30°C 0.0204 kg/kg dry air 816 kcal/kg 200°C us barg, Saturated liquid enthalpy at steam drum pressure: 352 kcal/kg, Calculate the following: a) Boiler efficiency using indirect method b)_ Specific boiler steam generation MT/MT of petcoke (Evaporation Ratio) 8 Marks 2Marks3 Sol _ a kg air / Theoretical Airrequired | ~((1-6:0.888)+1348x0.036.014/e+4.35x0.036) | (°F = 11.64 al petcoke 5 = (6/(2i-6)x00 % Excess Airsupplied — | = 19 % _ kg air / al Air supplied = (1+40/100)x11.65 kgof Ae = 16.31 petcoke ={(0-888%44/12)+0.012+(16.31%0.77) kgair/ Mass of dry flue gas +(16.31 -11,65)x0,234(0.036x 64/32)) kgof = 16.97 petcoke = 16.97x0.29x(250-30)/8430x100 Stack losses, L1 ee % boss due to formation of | _ a9 o36x(584+0.45*(250-30)}/8430x100 water vapor from H2in | = 3° fuel, L2 : % Loss due to moisture in | = 0.014x(584+0.45x(250-30)}/8430x100 fuel, 3 out % Loss due to moisture in | =16.31x0.0204x0.45x(250-30)/8430x100 Air, 4 =039 % Loss due to radiation and =10 convection % Loss due to unburnt in ash 205 % Efficiency of boiler using | = (100-12.84-2.63-0.11-0.39-10.05) indirect method 28253 % Heat added per unit of | = (816-200) kal py | steam generation =6160 Sm Heat supplied by fuel for | = (82.5/100)x 8430 eal steam generation = 6957 ° petcoke Specific boiler steam | os gig generation (Evaporation | ~ ° 97! Ratio) — \4 | Ina paper industry a coal fired boiler of 72% efficiency is proposed to be replaced with GCV of coal Cost of coal GCV of paddy husk Cost of paddy husk Quantity of steam requirement Enthalpy of steam 3900 kcal/kg Rs.12,000/MT 3500 kcal/kg Rs 9,000/MT 20 TPH = 760 kcal/kg paddy husk fired boiler of 65% efficiency. The boiler and steam requirement details are given below.Enthalpy of feed water =120 kealkkg Annual operating hours of boiler }000 hours Calculate the annual fuel cost savings by changing over to paddy husk boiler? \4 | For Coal Fired Boiler Sol Heat content in the output steam = 20000x (760-120) = 12800000 keal/hr Coal requirement 12800000)/(3900x0.72) = 4558.4 kg/hr Annual operating hours = 8000 Annual coal consumption 4558.4 x 8000 = 36467.2 MT Annual cost of coal 36467.2 x Rs 12000 = 4376 lakhs For Paddy Husk Fired Boiler: Paddy husk requirement = (12800000)/(3500*0.65) = 5626.4 kgfhr. Annual operating hours = 8000 Annual paddy husk consumption = 5626.4 x 8000 4501.2 MT Annual cost of paddy husk = 4501.2 x Rs 9000 =Rs 4050.98 lakh. 376- 4050.98. = Rs 325.02 lakhs Annual fuel Cost saving (5 | The co-generation configuration of a process plant along with relevant data are given in the figure below. If the extraction steam from the turbine is 8 TPH, calculate the following a)_Energy Utilization Factor 6 Marksb) Heat to power ratio, KW thermal to kW electrical ‘4 Marks S Sol 16 a) Energy Utilization Factor Total steam flow into co-generation system: 0.72 = X x (808-100) / (5000 x 5.44 x 1000) 19584000 = X x (808-100) X = 27661.0 kgs or 27.66 TPH Extraction steam flow = 8TPH Back pressure steam flow = 27.66 - 8 = 19.68TPH EUF = (Electrical ofp (Qe) + Thermal o/p (Q’)) / Fuel Input x GCV (Qf) Qf. = (6.44 x 1000 x 5000) = 27.2 Mkcals Qe =3x 1000 x 860 = 2.58 Mkcals Qt 8 x 1000 x(662-100)] + [ 19.66x1000x(649-100)] 4.49 + 10.79 = 15.28 Mkcals EUF = ((2.58 + 15.28) x 100 )/ 27.2 = 0.656 x 100 = 65.66 b) Heat to power ratio, KW thermal to KW electrical Qh = 15.28 / 860 = 17.77 MW 58 860 = 3 MW Heat to power ratio = 17.77 / 3 = 5.92 a) Two boilers A & B are delivering steam in equal amount to a common header, both at pressure of 15 bar. Boller A has super heater and Boiler B is without super heater. The temperature of steam supplied by boiler A is 300°C. The temperature of resulting mixture of steam in the common header is 235 °C. Find out the dryness fraction of steam supplied by the boiler 8, Take specific heat of superheated steam, Cp = 2.09 ki/kg. Properties of Steam at 15 bar: ‘* Saturation temperature, tex = 198.3 °C ‘* Sensible heat of Steam, hy = 844.6 ki/ kg. © Latent heat of steam, hi, = 1945.3 ki/ ke ‘¢ Total heat of steam, hy = 2789.9 ki/kg 5 Marksb) An oibfired boiler is rated for 10 TPH of saturated steam and pressure of 10 ke/cm? at F&A condition. The Boiler is operating at rated pressure with a feed water temperature of 60°C. Estimate the maximum possible steam generation at the operating pressure. The following, data is provided Latent heat of steam at 100°C is 540 kcal/kg Enthalpy of steam at 10 kg/cm? is 662 kcal/kg. 5 Marks t6 Sol ans a) Let us assume each boiler delivers 1 kg of steam. Then the mass of the mixture of steam in header = 1 + 1 = 2 kg. Using Heat and Mass Balance: Enthalpy from Boiler A + Enthalpy from Boiler B = Enthalpy in common header {2789.9 + 2.09 x (300-198.3)} + {844.6 + X x 1945.3} = 2 x {2789.9 + 2.09 x (296 -198.3)} a7 b) Ans: ‘Maximum possible steam generation = 10 x 1000 x 540 / (662-60) = 8970 kgfhr or 8.97 TPH. sssessseusee Bnd of Section = TIT .sssssssessse