Regular Paper 2 - Set B
Regular Paper 2 - Set B
Regular Paper 2 - Set B
Name : __________________
(To be written by the candidate)
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. Which one of the following is not true with respect to the role of nitrogen in the combustion
of any fuel
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Bureau of Energy Efficiency
REGULAR Paper 2 Set B
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Bureau of Energy Efficiency
REGULAR Paper 2 Set B
17. Heat transfer rate for indirect heating application will be less if we heat with
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Bureau of Energy Efficiency
REGULAR Paper 2 Set B
a) low Volatile matter b) low fixed carbon c) less ash d) none of the above
30. Which of the following boiler water treatment ensures complete removal of salts
a) 69.57 b) 4 c) 17.39 d) 16
34. The heat loss in a furnace depends on
a) High load under full pressure b) low load under full pressure
c) high load under partial pressure d) low load under partial pressure
37. The amount of CO2 produced in complete combustion of 18 Kg of carbon
a) 50 b) 44 c) 66 d) 792
38. Removal of condensate from main steam line is done to prevent
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Bureau of Energy Efficiency
REGULAR Paper 2 Set B
44. If the volatile matter in coal is low, which of the following equipment is the best waste heat
recovery option in a boiler
Calculate the electricity consumption in an induction melting furnace from the following melt
S-1
cycle data,
Ans: Theoretical energy required for melting = 1250 (0.68 x (1650 35) + 270)/3600
= 475.1 kWh
. (3 marks)
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Bureau of Energy Efficiency
REGULAR Paper 2 Set B
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)
(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)
Feed water is provided to a boiler from the feed water tank at 60oC, temperature of
S-3
condensate water returning to the tank is 88 oC, and temperature of makeup water is 27 oC.
What is the amount of condensate recovered ?
Solution:
27x + (1 x) 88 =60
Therefore x = 0.36
(36 percent makeup water or only 64% of condensate is recovered).
.(5 marks)
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Bureau of Energy Efficiency
REGULAR Paper 2 Set B
Milk is flowing in a pipe cooler at a rate of 0.85 kg/sec. Initial temperature of the milk is 60C
S-4
and it is cooled to 22 C using a stirred water bath with a constant temperature of 10C
around the pipe. Specific heat of milk is 3.86 KJ/kgC. Calculate the heat transfer rate
(kcal/hr) and also LMTD of the exchanger.
Ans:
= 124.678 KJ/sec
= 124.678 / 4.18
. (2.5 marks)
LMTD:
DT1 = 60 10 = 50 C
DT2 = 22 10 = 12 C
= 26.6 C
. (2.5 marks)
Paddy husk is being used as a combustion fuel in a water tube boiler. The ultimate analysis
S-5
of fuel is given below. Calculate theoretical amount of air required per 100 kg of husk for the
combustion from the following data.
Ans
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Bureau of Energy Efficiency
REGULAR Paper 2 Set B
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 -
. (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-6
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 Power
H = 760kcal/kg Alternator 0.7 MW
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Bureau of Energy Efficiency
REGULAR Paper 2 Set B
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)
Ans:
CH4 + 2 O2 CO2 + 2H2O
16 Kg of Methane produces 44 Kg of CO 2.
. (1 mark)
Considering 20% excess air,
= 10935 Kg/hr
. (1 mark)
% CO2 in the flue gas = 1375 / 10935
= 12.6 %
. (1 mark)
In a sugar mill, a process requires 5000 kg/hr of dry saturated steam at 7 kg/cm2 (g). For the
S-8
flow velocity not to exceed 25 m/s, determine the pipe diameter size for distribution of steam.
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Bureau of Energy Efficiency
REGULAR Paper 2 Set B
4 Volumetric flowrate
D
Flow velocity
4 0.333
D
25
D 0.130 m or 130 mm
. (3 marks)
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.
L-1 Write short notes on any two of the following: (5 marks each)
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Bureau of Energy Efficiency
REGULAR Paper 2 Set B
a) Find out the efficiency of the furnace oil fired boiler by the direct method in an agro product
L-2
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)
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Bureau of Energy Efficiency
REGULAR Paper 2 Set B
.. (3 marks)
L-3 a) In a typical fertiliser manufacturing plant, the quantity of 133200 Ton of Ammonia is
produced using naphtha as fuel as well as raw material (feed) and electricity from
captive power plant.
Naphtha Electricity
as fuel
Naphtha Ammonia
as feed Ammonia
production Production
raw plant
material
The quantity of raw material consumption and its heating values are given in table.
Raw material
Quantity Heating Value
consumption
Answer
a) Specific Energy Consumption(SEC) of Ammonia
Raw material
Quantity Heating Value Gcal
consumption
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Bureau of Energy Efficiency
REGULAR Paper 2 Set B
kWh
1250850
Ammonia 133200 Ton
production
Specific Energy Consumption(SEC) of Ammonia 9.39 Gcal per 2 marks
production = Ton
Answer
b) schematic diagram of (i)Back Pressure Turbine and (ii)Extraction Condensing
Turbine Cogeneration systems
As a part of energy conservation measure, APH (Air Pre-heater) is installed in a fired heater.
L-4
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
Efficiency of furnace : 69 %
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Bureau of Energy Efficiency
REGULAR Paper 2 Set B
Solution:
Amount of Air flow = 240 * 60 * 1.15
= 16560 Kg/hr
. (1mark)
Amount of fuel = 16560 / 17
= 974.12 Kg/hr
. (1mark)
Amount of flue gas = 16560 + 974.12
= 17534.1 Kg/hr
. (1mark)
Heat absorbed by combustion air = 16560 * 0.23 * (250 30)
= 837936 Kcal/hr
. (1.5 mark)
Temperature difference in flue gas = 837936 / (17534.1 * 0.26)
= 183.8 C
. (1.5 mark)
. (2 marks)
ii) mh ch (th1 th2) = mc cc (tc1 tc2)
th2 = 44.6 o C
..(3 marks)
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Bureau of Energy Efficiency
REGULAR Paper 2 Set B
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)
..(2.5 marks)
LMTD = 28.54oC
Q = UA (LMTD)
= 445816
800 x 28.54
Area =19.5 m2
..(2.5 marks)
A process industry is equipped with a steam power plant generating 1,25,000 units/day and a
L-6
separate low-pressure boiler generating at an average steam production of 9.5 Tons of
steam/hour at enthalpy of 630 kcal/kg for process heating. The feed water temperature to the
boiler is 62oC.The efficiencies of the steam power plant and boiler are 27% and 78%
respectively. Coal is used in both cases and calorific value of coal is 4000 kcal/kg.
The management proposes to commission a cogeneration plant retaining the coal as fuel.
The expected energy utilization factor of the cogeneration plant is 75%.
SOLUTION:
Heat input for separate production of = (125000 x 860) / (24 x 0.27) + (9.5 x (630-62)
power and useful heat x 1000))/0.78
= 16589506 + 6917949
= 23507455 kcal/hr
. (4 marks)
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Bureau of Energy Efficiency
REGULAR Paper 2 Set B
Heat input with cogeneration plant = [(125000 x 860) /24 + (9.5 x (630-62) x
1000)] / 0.75
= (4479167 + 5396000) / 0.75
= 13166889 kcal/hr
..(4 marks)
Coal savings = (23507455 13166889) / 4000
= 2585 kg/h
..(2 marks)
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Bureau of Energy Efficiency