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Gujarat BOE-2013 Paper-1 (Boiler Engg-1) Solution

Q. 1(a) : A boiler of 20.43 m3 capacity generate steam at pressure of 8 bar where

2/3rd volume is occupied by water and 1/3rd volume by steam. The explosion takes
place. Calculate the energy released due to explosion if the period of explosion is
one second take density of water at 8 bar at saturation temperature=896 kg/m3.

Solution : Take r(Gas constant)=1.4

Given that
P1=8bar
Volume of steam generate at 8bar=20.43M3.
Density of water ϱ=896 kg/m3
P2=ϱxg=896x9.81=8789.76kg/cm2=8.78bar

Energy released due to Explosion

E=[(P2xv)/(r-1)]x[1-(P1/P2)(r-1)/r]
E=[(8.78x20.43)/(1.4-1)]x[1-(8/8.78)0.4/1.4]
E=[(179.3754)/(0.4)]x[1-(0.91)0.286]
E=[71.75016]x[1-0.973]
E=71.75016x0.027=1.94joul

Q. 1(b) : The ratio of the base radius and the height of a cone is 5:12. If the area of
base of the cone is 616cm2. Find the curved surface area of cone.

Solution : Suppose Cone base radius is “5a”cm & height is “12a”cm.

Area of base of cone=π.r2
616=3.14x(5a)2
Or 616=3.14x25a2
Or (a)2=616/78.5=7.85
Or a =√7.85=2.8cm
Code radius=5a=5x2.8=14cm & Cone height 12a=12x2.8=33.6cm
Area of curved surface of cone =π x radius x height
=3.14x14x33.6 =1477.056cm2.

Q. 2(a) [i] : Sketch and shortly describe a Ramsbottom spring loaded safety valve.

Answer : Ramsbottom spring loaded safety valve : A pair of plug valves were used,
held down by a common spring-loaded lever between them with a single central spring.
This lever was characteristically extended rearwards, often reaching into the cab on
early locomotives. Rather than discouraging the use of the spring lever by the fireman,
Ramsbottom's valve encouraged this. Rocking the lever freed up the valves alternately
and checked that neither was sticking in its seat. Even if the fireman held the lever down

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Gujarat BOE-2013 Paper-1 (Boiler Engg-1) Solution
and increased the force on the rear valve, there was a corresponding reduction of force
on the forward valve.

Q. 2(a) [ii] : Draw single line diagram of steam condensing plant showing each and
every item with names as well as flow of water and steam.

Answer :

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Gujarat BOE-2013 Paper-1 (Boiler Engg-1) Solution
Q. 2(b) : Calculate the specific weight , specific mass and specific gravity of liquid
having a volume of 6 cubic meter and weight of 44kN.

Solution :
Weight of liquid=44kN=44000N=44000Kgm/s2
Mass of liquid =Weight of liquid/acceleration of gravity=44000/9.81=4485.22Kg
Volume of liquid =6 m3
Specific Mass [Density] : Density is defined as mass per unit volume. Mass is a
property. If ρ = density (kg/m3) ,m = mass (kg), V = volume (m3)
ρ = m / V = 4485.22/6 =747.54 kg/m3
Specific Weight : Specific Weight is defined as weight per unit volume. Weight is
a force. If γ = specific weight (N/m3), ρ = density (kg/m3), g = acceleration of gravity (9.81
m/s2)
γ = ρ g =747.54x9.81=7333.37N/m3

Specific Gravity [Relative Density] : Specific Gravity - SG - is a dimensionless unit

defined as the ratio of the density of a substance to the density of water - at a specified
temperature. If SG = Specific Gravity of the substance ,ρsubstance = density of the fluid or
substance (kg/m3), ρH2O = density of water - normally at temperature 4 oC (kg/m3)

[It is common to use the density of water at 4 oC as a reference since water at this point
has its highest density of 1000 kg/m3.]

SG = ρsubstance / ρH2O =747.54/1000=0.74754

Q.3 (a) : In a surface condenser, vacuum maintained is 700mm of Hg. The

barometer reads 754mm of Hg. If the temperature of condensate is 64.4*F.
Determine-
[1] Mass of air per kg of steam.
[2] Vacuum efficiency.

Solution :
(i) Absolute pressure =760-700=60mm of hg=60/750=0.08bar
At 64.4*F(18*C) condensing steam temp corresponding saturation pressure will be
0.02062bar
Partial pressure of air= Absolute pressure-Saturation pressure
=0.08bar-0.02062bar=0.05938bar=0.0586kgf/cm2
PV=mRT
Mass of air per kg of steam m
=PV/RT
={0.0586x10000x23.741}/{0.294x(273+18)}
[1Kg/m2=10,000Kg/cm2]
[Volume steam space at 0.0586kg/cm2 pressure is from steam table is 23.741m3/kg]
[Value of R for air =0.294]
=13912.226/85.554 =162.61339kg/kg of steam

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Gujarat BOE-2013 Paper-1 (Boiler Engg-1) Solution
(ii) Absolute pressure =760-700=60mm of hg
Corrected vacuum=760-60=700mm of hg
Ideal Vacuum =Barometer reading-Condensate temp corresponding pressure
(18*C saturation temp corresponding pressure is 0.02062bar)
=754-(0.02062x750)=754-15.465=738.535mm of Hg
Vacuum efficiency =[Actual vacuum/Ideal vacuum}
=700/738.535=0.9478=94.78%

Q.3 (b) : Find out the height of a chimney on basis of following data :
Static draught=30mmwc, Flue gas temp=230*C, Ambient temp =30*C.
(Air and flue gas density NTP are 1.293 and 1.34 kg/m3 respectively.)

Solution :
Suppose H=Height of chimney to produce a draft
Given That,
Ta (Ambient temp) is 30*C=30+273*K=303*K
Flue gas temperature T=230*C=230+273=503*K
Static draught h=30mmwc
Taking the volume of 1 kg of air at 0oC and 760 mm of Hg as 0.7734 m3,
Mass of air =Volume of air x density of air
=0.7734x1.293=1.00
Weight of air required in kg for burning 1 kg of fuel w=Mass of airxg
w=1.00x9.81=9.81kg/kg of fuel burnt
According to Avogadro’s principle, at NTP, the volume of gas will be the same as the
volume of air at NTP.
Theoretical draught “h”=353H(1/Ta-{w+1/w}x1/T)
30=353xH(1/303-{10.81/9.81}x1/503)
30=353xH(0.0033-1.102x0.00199)
30=353xH(0.0033-0.0022)
30=353xH(0.0011)
30=Hx0.3883
H=30/0.3883=77.26 meter

Q. 4(a) : Find out the lower calorific value & higher calorific value of following
gaseous fuel : Volumetric composition is CH4=69%, C2H6=29%, N2=2%
HCV of gases : CH4=39000kj/Nm3 and C2H6=71500kj/Nm3.

Solution : Unable to solve

Q. 4(b) [i] : Give comparison between Forced draught and Induced draught
system.

Answer : Comparison between Forced and Induced Draught Systems:

1. Forced draught system requires less fan power, since the fan has to handle only
cold air, where as in induced draught system, fan has to handle comparatively
more volume of hot flue gases.
2. Forced draught gives better control than induced draught, as air penetrates into
the fire-bed or helps in good turbulence and thorough mixing of fuel than in
induced draught system and hence rate of burning of fuel is faster and efficient.
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Gujarat BOE-2013 Paper-1 (Boiler Engg-1) Solution
3. With forced draught system, possibility of gas leakage is always outward and
hence there is always risk of hot gas blowing out if any peep hole or inspection
doors are kept open.
4. With induced draught, all leakages of air are inward and therefore, heavy air
infiltration will occur if refractory and brick work etc. in the flue gas path is not
maintained in good condition, resulting in over loading of Induced Draught Fan.
5. Blades of an Induced Draught Fan get eroded and corroded faster than a forced
draught fan, since it has to handle erosive and corrective combustion
products.Hence Induced Draught Fans are require more maintenance.

Q. 4(b) [ii] : Why steel chimney are more preferred in Gas turbine power plants
than any other chimney?

Answer : A gas turbine unit archives full load in less than a minute and such the
chimney has to withstand a thermal shock resulting from the increase in temperature of
450 to 500*C during this period. The thin walled steel chimney having high thermal
conductivity is bes fitted for accepting such a load.

Q. 4(b) [iii] : Explain the purpose of using super heater in thermal plant. Describe
any one reliable method of super-heater temperature control.

Answer : Purpose of using super heater in thermal plant :

The steam coming out from drum through saturated steam pipes is dry and saturated.
The saturated steam flow takes its passage through set of coils, called Super-heater,
where further heat is added to increase steam temperature at constant pressure. Degree
of superheat of steam has to be increased by flowing steam through super heaters. As
well as Enthalpy of steam being increased through superheating process i.e. heat
addition can be increased in same quantity of steam. In thermal power plant turbine
needs only superheated steam hence provision has to be made in such steam generator
to ensure quality steam.

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Gujarat BOE-2013 Paper-1 (Boiler Engg-1) Solution
Super-heater temperature control method/ Attemperation Process :
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. 4(b) [iv] : List out different methods used in practice to heat up air in air
preheater.

Answer :
Types of Air preheater : There are two types of air preheaters for use in steam
generators in thermal power stations:
1. Recuperative Air preheater
(a) Tubular Type Air pre heater
(i) Metallic recuperative
(ii) Ceramic recuperative
(b) Plate Type Air pre heater
2. Regenerative Air preheater
(a) Rotating-plate regenerative air preheaters (RAPH)
(b) Stationary-plate regenerative air preheaters .

Q. 5(a) The steam condensed in a surface condenser is 12500 kg per hour and the
amount of air leakage is 5kg/hr. The vacuum near the suction pump is 70cm of Hg
and temperature is 34*C. The air and condensate is removed by a wet pump.
[1] Find the capacity of wet pump if the volumetric efficiency of the pump is 80%.
[2] If the air-pump runs at 100RPM find the dimension of pump required.
Take L=1.5D and assume pump is single acting. Take barometric pressure=76cm
of Hg.

Solution :
[1]Absolute pressure in Condenser = (760 – 700)/750 = 0.08 bar
At 34*C, the partial pressure of vapour = 0.05358 bar
Hence partial pressure of air = 0.08 – 0.05358 = 0.02642 bar
Volume of air at this condition = 5.0 x {(0.7734 x 1.0133) / 273} x {(34 + 273) / 0.02642}
=5x[0.00287x(307/0.02642)]=5x33.35
= 166.75 m3 per hour
At 0.08bar pressure of condensate corresponding specific volume is 0.001008m3/kg
Hence Volume of condensate = mass of condensate x specific volume
=12500 x 0.001008 = 12.6 m3
Wet air to be handled by the pump = 166.75 + 12.6= 179.35 m3 per hour
Volumetric capacity of the pump required =Volume of wet air/Volumetric efficiency
= 179.35/ 0.80
Capacity of wet pump = 224.1875 m3/ hour

[2] Volume handled, m3/hr =(π/4)D2xLxNx60

224.1875 =3.14x D2x1.5Dx100x60
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Gujarat BOE-2013 Paper-1 (Boiler Engg-1) Solution
224.1875 =3.14x1.5D3x6000
224.1875 =28260D3
3
D =224.1875/28260=0.0079
Bore of pump D=0.199m=19.92cm
Stroke of pump L=1.5xD=1.5x19.92=29.88cm
Mass of water vapour going with air
=V/Vg at 34*C=224.1875/26.601=8.43 kg/hr
Dimension of pump;
Bore of pump=19.92cm,
Stroke of pump=29.88cm
Mass of water vapour extract with air =8.43 kg/hr

Q. 5(b) : Calculate the thickness of the material required for a cast iron main 800
mm in diameter for water at a pressure head of 100 meter, if the maximum
permissible tensile stress is 20MN/m2 and weight of water is 10 kN/m3.

Solution :
Given that
Diameter of cast iron d=800mm=0.8m
Max permissible Stress ϭ=20MN/m2
Weight of water w=10 kN/m3=10x103N/m3
Head of water in the main h=100meter
Thickness of metal =??

We know that
P =wxh
=10x103x100
=1x106 N/m2
Using the relation ϭ=pd/2t
Thickness of metal t =pd/2ϭ
=1x106 N/m2x0.8m/2x20MN/m2
=1x106 N/m2x0.8m/2x20x106N/m2
=0.8/40
=0.02m
=20mm

Q. 6(a) : A lever safety valve is 75mm diameter. The distance from the center of the
valve to fulcrum is 90mm. The lever is 61cm long from the center of the fulcrum to
the center of weight at the end. The lever weighs 4 Kg and its center of gravity is
25cm from the fulcrum. The valve and spindle together weights 1 Kg. What should
be the weight at the end to blow off the valve at 4 Kg/cm2?

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Gujarat BOE-2013 Paper-1 (Boiler Engg-1) Solution
Solution :

Q. 6(b) : Explain the principle of reverse osmosis. Draw sketch showing sea water
treatment plant using reverse osmosis system from start to end.

Answer : Principle of RO(Reverse osmosis) : Reverse osmosis uses the fact that
when solutions of differing concentrations are separated by a semi-permeable
membrane, water from less concentrated solution passes through the membrane to
dilute the liquid of high concentration. If the solution of high concentration is pressurized,
the process is reversed and the water from the solution of high concentration flows to the
weaker solution. This is known as reverse osmosis. The quality of water produced
depends upon the concentration of the solution on the high-pressure side and pressure
differential ascross the membrane.This process is suitable for waters with very high
TDS, such as sea water.

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Gujarat BOE-2013 Paper-1 (Boiler Engg-1) Solution

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