<,

IS
GOVERNMENT
.

t~E
/~
f ~,)

Ioo

LLrt ~ !:J

...

-----------

Jz_

OF KARNATA~A

~
~

''h:,''<.o,'''''_'

~"""~/

(Dq1:1rtment ofF,lctories

& Boiiers},
Examination)

!!i

Boiler Operation

Engineers

Time _ 2.00 hours

Max. Marks - 100

Subiect: Boiler and Heat Engines All Questions carry 4 marks each

, i

I /1
;(}'/?'

C():;o:cL

{~:>
teml~~1_~defined, comer? ~.\(, \~

.//' 91. desIgn? Ho~v is the

Az. Wha~ is a down

/'

/---

. -

arId how does this tenn affect wt boiler

3J~I S'3. {,

/'

..

'

r .....

' I
(hth\\') unit?

;t,\,

~3. What is Combustion

and them1al efficiency ~ithe

Boiler ..~ .,; f. ~ '< ..'

Q4. \Vh~n does a boiler become a high-temperature

;,,< ..,jQs,.\V~lat is t!lt~meaning. or pH in w~ll:~r chemistry?
'"7~~. /'

hot-water

'l1' ~
-'

'!'

.~ 06. "Vh:,t three: DUrl)OS7CS7 ..

A:J.7.

,11='c::: :;

b!o\'

dO\VI~

valve serve?/' p ,t.(, t--L~-'v 0

In what manner is the quality ofa weld checked? precautions needed to prevent furnace ,~xplosionV

ffi List the operating

~at ~

is the purpose ofan Economizer~' Name the two methods uf analyzing

~~.y
/' coal?

b' ~
What ar~ the t'NO major ~ \ "\ .

~12:

QlJ-",Namc three scale COllning properties of water?

objections to sC:lI~ in a boiler?

v~

What

.. IS the

' / purpose of! D and ID {<ans?

1- -<111--.&.
P 'J(

~Plai

n the teon heating val ue 0 r fEeJ?

V/

tVJ'iJ

I!

Jj

;,,,~~Q14. '.'':hy 'vc ir.s!;>Jf11cntsirnrortant

[('I' })roperly operating

c

a steam gen~rat0~ or

v/<;;'ti~p;?
~.

.
:l

~.

Explain the din~~rellce bl (wecn valve? /

rciicfvalvc

and an SV

What is a safety relief

-Qf6.
.~hat

What arc the comIllon or primary mCJSuremcnts

used in controlling

i~: carry-over, and how is it' callsed;-

\ ~

r'

boilers?

~! Ii
.,,1

~~a; ~~Vhat
I

area of the boiler shaH be computed as heating surface?; is an operator's first duty wlten taking over?

Name four causes 0 [failure in ,ubes of waler tube b oilers?~ causes priming and foaming/-

~JT:Wbat ~at , /'

i'

'Ii"

Ij,~rt
.

is mean' by ion exchange in wate(IToa,men,';'

('").....

Iq.r ~I'!.)

~i
'S.
Ii,"
I)

In what unit is draught is measured? ,/"

1.
:~
i
Ii

",Q24, What is meant by

eXcess

air ,& why it is necessa9C? .f,"", ~

How is furnace heat transferred to the waterwalIs? / ~

------

-~------

GOVERNIVlENT

OF KARNATAKA

OEPT.OF FACTORIES AND BOIU:RS

BOILER OPERATION ENGINEER'S EXAMINATION

Subject:

Drawing

max.marks:
Time:

100

Ji hours

All questions

carry equal marks

1) DRA \V A ~E.~ T DL-\GR,-\

\f OF A SPRi '-,G LOADED SAFETY \-\L \',E \fOtTi'JTED ON A STE\),[ DRC'vL L-\BEL The PARTS') EA'PLAI?-~ \VI-{Y A DRll\[ S.-\FETY \'Al IS SET AT h1GHER PRESSt'RE tHAN THE BOILER OLiLET STL\.,\'[ LP\Jt SAFETY VAL \, t.--;

vt

2) DRA\V EXPLAiN A\- OIL BCR... '\t:R ASSE'vIBL Y PRO\1DED hiGH PRESSURE BOILER 3) E;{PLi-\IN' WITH A '\t:AT SKETCH HO\V DOES A 3 ELE\'fE);[ LEVEL CONTROL OPERATES rN A BOrLER'i 4) ):AlviE TEE PARTS OF Tl-it. VAL '-.1: GfVEN fN THE

,~~u

f\.-\

DR(;~[

DtAGR..-\\ L

.,

~OVERNMENT

OF KARNATAKA
, , I I

(Department (Boiler operation Time - 2.00 hours

of Factories & Boilers)

Engineers Examination

- January ~002) Max. Marks - 100

~ubiect:
The last Question is compulsory carry 3 marks each. Q.1 What is a down comer?

Boiler and Heat Enaines,

and carries 10 marks anc. all other questions

'~.;'--W~lnd
Q.3

of boilers are used in wast:'heat applications?~~J-b

1'*

'15

What is meant by nondestructive

test?

QA
Q.5

Name the two methods of analyzing coa,. What are the usual percentages of excess air in burning the vari:Jus common fuels in boilers? Whdt is meant by balanced draft? ) 1- . t.

9..6

Q.7 Q.8

Explain the term heating value of fuel? List the operating precautions needed to prevent furnace explosions.
\'1.
1

\//,: '

..

.';

;::'VVhat
'ft,;.'\. ... ~ >'I'i.

is the purpose of an forced draught and induceddraught fans?

What are the two

Q.l0 ~ Name three scale forming properties of water? . major objections to scale in a boiler? Q.11 "W~t:lsthe Q.12 Q.13

'~I

Of'

pr~mary function of a flame safeguard system?

Name some safety controls on a boiler. Why'are instruments important generator or boilers? Explain the difference relief valve (SiV)?" for properly operating a steam -

Q.14

between a ielief valve and all

sv.

What is safety
I

GOVEF<lJ

1'-1

tNT

QF f<ARNA T AJ<A

(Department

of Factories & Boilel's)

S~~

j"

II

Time _ 3.00

rlOLlI"S

~1cIX. Marl<s - 100 ~JJ

b~st:

BOiler a riel ~Ieal: Enq i-nes. .......

.-

Ttle last Question is cOlllpulsor'y and carries 10 marks and all other questions Carry 3 marks e(lch .
k":,, . ... , . ,

Q.l
!

vij~a

down comer? applications? .

I~

Q.2

What Kind of boilers are used in waste-heat What is mearit by nondestructive test? coal.

Q.3

QA
-Q.5

Name tile tY'IO methods of analyzing Wrlat are the ustJell per'centages COlllmon fuels in lJoiler'sl

of eXf~~S air in bu 'ning the

VC1(ious

, V' "Q.G

Q.7 Q.S

EV[J!;::';"""'0 '-C'{'I" i)~C1li.'c.! /\....... ', I I LI I . l,II ( l..J . ' I I _i

,-,-"fUr-'>

C,

-,I' U I fuel? ',/

---

List the opel'atlllQ what

pr'eciJutio"s'rleeded

to prevent fumace explcsions. and indlced drilUg11t fans'

i')'\ \.9/) ." '0

Q.l1
Q.12

is tl,e purpose of an forced draught

"(JJ"~three scale to fonnlng plOpertieS major objections scale in a boiler? of water?

\N~IClt i:; the pr'ifl1:1ry function

W lat are the two system?

of a flame safeguard
(l

NalllQ

~~OllIC

sufety contr'ols on

boiler.

'"

Q.13

Wily an: instruments inipor'tant generator or boiler's? / Explain the difference relief vaive (siv)l between

for properly

operating

a Sle<Jrll
i

Q.14

a relief valve and an sv. What is sofety

'",-"",""

""""~'

"

,
'~\

,
, 1",:

'\, ~} "'-, '

\;I

",",,- \ ')
\.

_" J_) , i

Q.15
Q.1G;"",\Al~1~,tClreaof tile boiler
.",~>,

sure settings

for :wo or more SI/S

Sll<:.ill
,"

,Q.17
III i

What is carry-over,

arld how is
ret:luce

Q.18
Q.19

How does

C9 deaeretor'

\:~'l

What causes priming

and foamin
, I

Q.20
Q,21 Q.22' Q.23
/' Q .-"""':" -.
<

What harming may wiming i.~ foarT1in~J ~b? /' Name four causes of failure in tubes of water tube boilers? \Nhat are tile combustible \Vhat elements In what unit i elements in fuels? /. to metals?"

\
\II

in fuel are harmful Light is measured7 appliances

Q.:25

Vvhat are the minimum

of appurtenances

n,=cessary for safe

n
.p

;"",.j:dQL!er operation?,..~;.,;~::.,;.~;"
'Co::;

"",0 __ I

What is meant by pulverized

(oall .

Q,27 Q.2S
Q ./..~ -. r-.

What is meant by excess air & why it is necessary? What causes rnost external corrosion?..--

Vi/hat is tile purpose of an Economizer? Where should gauge glass be located?" What hydro static pressure should be made on a water tube boiler,v all welded construction of 92 ems. 1D shell plate thickness 1.6 ems. tube shee.t 2.0 ems. thick? Ligament efficiency of tube holes longitudinally is 43:5 %( girth wise it is 20%, longitudirally weld efficiency is 90%, aliowable stress 960 kg / em2

Q.30

'k ..... ..,; ..

Chhattis!2,arh

Bo~kr Uoeratioll

Lll~~IJI~~I:< LXallliJI;ltlUll

2()()7
iUO

Q- j lick the corn:CI al1'iwn I) TIle btcn! heat IS supplir.:d

;1

ill

buller

:ll-

(21) \

2\1

Supcrhcal~r.
DO\\lICO/IICf

b.

ii)

c Rehc.:llcr '.reI. Watcm;1I1 Three c1eincnrs of drulll level cOlllral are~ StCClJII F10\\. feed flo\\' ,lIld drU111le\cl Drulll Ie\ cL Drulll pressure and S(C<llllnOlI . Drlllll k\ cl. SIC,lIll Icmlx.:r,llllrc and bolicr II'lI..:r ICIIIp;.:I;;t,ICl Onlill k\.:1. [)nlill prc~sur.: ;111<1 [)nllli \\;Ikr i<.:lllp<.:r'llllIc .\liIl jillcllcs~ fuc LlIllJlllllllllS <.:o,11 ~llUlIlJue ~ 70 % of pul\crized coal p,lsses through l!JO IIle,ll.. b .. (,(J% of pulverized coal p:\~)~csthrough 2\HI nlc)1l

b. .: d

1\ )

c. :10% of pulverized coal retained at 100 Illcshcs d. lu'!i;,of pull cnzcd co:lllct;ullcd ilt 50 IIh:~,III:~ III ;\ boiler hydra/JIlC is led at lJ. !\;.Iin Sl,,:llll a. Boiler drum
c. Reheat
COrrOSIC!1
SrC<llll

line

OFP Sllctlon b EroSIOll

111I':

I) ~:

ACid dew !XJIIII is rclated 10

:"lJr;I~I<J;;

\ I!

V
h
l.

UUfllcr

tilt

I:, ~\.T,cc::Ih II,-cd IllJ

'-;IIIXT

I !'.,i l':~_1\,,:I:1i

i "lllp, .. r:11iir': ,:("11;,

1(t: lll..:~!~ .: .r ')II...'.!I:! !;..'It;PL'LJllili..' \.\jUllld

Ur~lu~:.li~ ,,-Ullt/(d
;Z~lnhilt...: (, 0110 C\:::ic ~:"

\ Ii)

d Abu\::: ,Ii; \\ lu~h cy'.:l(: 1:, litO...,,! clft(:icni

~ CaniO(
Di<.:,..:1 c.-\..:!c
c:

l '.elL:
(j'''':

11

\'~\i

hi.)dcr \\;t{(;{

;,
L'
1".1

pH .,ljl~)tL:Li Lc~~ ilL .. : \ \iUf:..' I::. J' ',J '

,.. -:.>:-

ill \uCllon

I\P( lltl[,. .\. 8dore 11;;~:

'01' COlllbu,llllll

t~ '\ 1::-. l~)(;I(\.:~!

~
;tIC -

.. \il:::lllllii
~i..)I\L:0[' :iLu'. ~

.\ )

,rs
vtJ.
C. d

;1.

Time, TClllpcr:illlrC ;llld Tokrancc Turbulcllc:, TCI:q>CLllliI( ,IIIJ Tilll::: Tiule, Tllr~L1\(:uC(; ami TGicuIlcC TucL\uic:t.;(, Tlllq,c:r.lil:~:::
,J!I(j

TolcLlii-\.

\A( -I\Lll th,ll)!

c ?:.:r:pilcr::! It,\11:

,1',1(,;
, : I":"

::,ill';
\.':

,!

t." ~ .... '

~IO~~:IIIUIL':lr~l:; '.;litl~\
;1 ...i.ir prCSL'1l1

Ul-,lir

\:;~

I!,

lL,_'

:JI!!1i...1::-.pL .... J<. l..'

)-;

\!f
'. !)

r~:q:l~!,,~(:! -':\lili;)k':,:
i,~ ~I:; I I ,

i':"!:

(Jf-!,

i:;l

1\

ll"\,_~':~

I'

I,,;",j

,-'. i

?O

C)

b
Max. Marks : 100

Chhattisgarh Boiler Operation Engineers Examination 2006

Time: 3 Hours Boiler & Heat Engines Q-I Tick the correct answer: i)
~

ii)

J
iii) ~ iv)

The first law of thermodynamics states that (20 X J )=20 Heat and work are mutually convertible. b. If two bodies are each equal in temperature to a temperature of third body tlley are equal in temperature to each other. c. Change of internal energy is proportional to the change oftemperaturr. d. Heat can not flow from lower temperature to higher temperature without the aid of an external agency. Second law of thermodynamics states that a. Heat and work are mutually convertible. b. If two bodies are each equal in temperature to a temperature of third body they are equal in temperature to each other. ~ "Z.oa-J.n ~ c. Change of internal energy is proportional to the change of temperature. Heat cannot flow from [ower temperature to higher temperature without the aid of an externalagency. Zeroth's law of thermodynamics states that a. Heat and work are mutually convertible.

v)

If two bodies are each equal in temperature to a temperature of third body they are equal in temperature to each other. c. Change of internal energy is proportional to the change of temperatw"c. d. Heat cannot flow from lower temperature to bigher temperature without the aid of an external agency. In thermodynamically reversible process when heat interchange is zero, the process is known as t--l:r Adiabatic process a. fsopiestic process. c. lsochoric process d. Isothennal process In thermodynamically reversible process when change in internal energy is zero, the process is
known as

lsopiestic process. b. Adiabatic process lsochoric process vcr.- Isothermal process vi) main purpose of reheating of steam of thermal plant is To increase dryness fraction of steam in LP stage. Reduce the blade erosion and improve blade efficiencies in LP stages. Increase thennal efficiency ~ Above all vii) For protecting magnetite layer in boiler tubes, the pH of boiler water should be a. Less than 8. L-@-etween 8.8 to 9.2. c. More than 9.8 d. None of above viii) In trisector regenerative Air preheater boiler, PA fan handles the \AI. cold air b. Hot air c Tempered air of mill outlet d. None of above.

a. c. The a. b. c.

sk ix)
x)

Circulation Ratio range of~igh pressure (100-160 Kgf/cm2) utility and industrial boiler is a.50to15 ~14to9 c. g to 4 c. 3tOT The amount of nitrogen in coal is determined by: a. Its proximate analysis;.~ C i H 2,..(; I V M , A-s h c. v_ b.' Burning it completely in air; .v@' Ultimate analysis; d. Burning it in the absence of air;

fS (

\e

Y --

"

, \' I

\, ,

xii) As pn IBR-1950 regll'~lli(l1l :;I(),;t stress I'L'lil'l,ill~', Ilc'<lIII'L'<lllllellt ,h<lll 11<: r<:rl<mTl<:df<lr c~lrh(Jn steel by heatin~ the pal1 to at least ------------ "e, xiii) As per IBR-1950 regulation 327( e) pressure gauge shall be calibrated within an accuracy of ______ % and boiler pressure gauges shall not be less than --------mm diameter, xiv) In a balanced draught system--m-----fan and -m----fan are provided. , xv) In a very high pre)urc sub critical boilers forced circulation pumps nre provided to circulate water through tubes as --~-------- is low at high pressure for natural circulation, xvi) /\ vessel contains a niixtllre of saturated water and saturatl.:d steam at a temperature ol'211'i{lc. then the pressure of the vessd wi II be--------- bar. ' xvii) Steam at 19 bar is throttled to 1 bar and the temperature after throttle is found ,0 bc 150"e, , the initial dryness fraction of steam was __n xviii) Steam at 5 bar 250C, expands isentropically to a pressure of 0,7 bar, the find condition or dryness fraction of steam will be----------, ( Use: steam table for 0-2 xvi t<>xviii) Q-3:, .- Use steam table for solvjng follo\'1ing questions . (5X4)<~O i) Water is supplied to the boiler at ) 5 bar and 80"C and skarn is generated at the same pressure at 0.9 dryness. Determine the heat supplied to the steam in passing through the boiler and change in entropy. ii) O.S.Kg of steam 3t 4 har is contained in a cylinder fitted with a piston. The initi:li \olume of stc'an, is 0, I m), ~k:lt is transferred to the St.:~II~l:It constant pressure until till: k';lpc'I:ltLire becomes 300(\( (ktLTlllinc the h~at transfer ~liiLi\1 \,rK done during thl.: proccs,;

i,I i , ,:1 i
i

II , I! 'I

ri
r

...

'I :Il"

iii) A

certain quanti,y

of dry and saturated

steam

~lt I:' har occupies

initially a \ollll11e

0"

2.32 1111 It IS (;ul1lpre~~(;J until the vulullll: i~Ildl\(;J: a.lsothermally. ' ~ b. As per the law pv =constant. Detennine the final condition orstealll in <-'deli l<l'<-'" 1\1, () JekrIninL' the isothfmal process,

the he;lt reiL'Clc'J during

iv) Steam enters a turbine at a pressure of lObar ,\lId 300"C with a velocity of 50 m's, Thl.: steam leaves the turhine at 1,5 bar and with a velocity 01'200 m!s ' Assuming the process to be reI eFSibil: adiabatic and negkctill~ tilL' change in f)utential ene 'g;. uell:rIllillL' k; ~~:':;:~:ln-1nu',.\' tbr~~\.~g.L :!~,.:~~;;'~/iil':' the \vork dene p.:~ v) Steam at 10 bar and :;00"('. passing through Ctllll'l.:rgcnt divcrgcllLl10zzk exp:lI1d" n.:vcrsibk
<!

and adiabatically till the pressure falls to:2 hM, Irthe velpcity is 50 m/s, determine the exist velocity of the ~1':~II11,
Q_~

of steam entering

into the
( IOX2)

i)

What is Circul.1tionl{alio olboikr and wlLlt slwuld be CRs range for nat lral circulation Boiling circllit for hi~1t stcam pressur.: ( 1 :,()(J to 210() psig) in large lItility anJ industrial boiler') ,

ii) What is the purpose ofboi1er drum and what :11',: the main componcniS of drulll il1lcrnal " iii) What are the \2.rious heat losses in PF bOiler helng eunsidercd It'l' ass..:ssi 19 hlilel efficiency thrc'ugh loss method " iv) Wltat is the PU:i='U"C 01 \)e~IClalur \'h~ll.<1', '~,~ eltc'lllicclh hL'illO:d","c',\III" "',, "I:e ~111,: fCI.:J line and \,;,;')
',J

v) What is the PI1::'\'"C' ,,1'11',1) :llld ell\) ',' ,:",c, ,iiLlii \Iilh I'\lugh sf..I'[(iIL' vi) lira\1 the Sdlt,':",Hic 1:,1\\ :Ilh! Iherm,iI c~ck ,.;:,::.:I~IIIlITS) ofthel1l1~li 1'\1\\el' i"'I~:
vii) 111..)\\- do >~ltll..,';nL
t\"\

f.,.lh)\\ [h~H th~rl..

i ..... C~1jh;I..':hcr tuhL.: Il..:ak,,~~

ill rlll1111il~ U,"i:

,;ihl \\lLl!

action do you ::lKC 1111 oh';efling slIchahrwr:n:i1ilie<' " viii) What is the rurpo~e or prilllary and SeCOllll<ll> ,1II fur Pi: boib" ix) As per IBR-lu:,O re~ulalion 291. what arc II:e Jilkrentt;pe orsakt\ i"nboilers In I,',['CCI ,1I":I\\C lir ... , ,x) \\'ritc shur; 11\'- _. Oil \.:Jti",tic :,,In:'\rit{!l.'l~;,-I\'

1:111c', bei,,!.: used

n
OJ: (\
i

xi)

Swichiome;;u'ic quamity of air is Lilt a. Some excess oxygen left. air. c. 50"% ex~

qUl1l1lity

of air required for complete combustion b. No oxygen left unused d. 1QUO/o excess air. b. NCV at constant pressure d . NCV at constant volume

of fuel with

\ xii), Bomb calorimeter is used to determine ,_. a. GCV at constant pressure c. GCV at constant volume

xiii) Proximate a. C,H,N,S analysis is determination oJ~cntagc & H20 of fuei U IH~ . H20,ashof and volatile matter Q. Conly. d. Useful heat evolved. xiv) lncomplete combustion can be best judged by a. Smoky chimney exit. b . Excess air in flue gases c. Measuring C(l in flue gases. d. Measuring C(h in flue gases. xv) Lignite is a. Lowest rank coal. b. Highest rank coal. c. Used in metailurgy of iron d. Comains no moisture xvi) Hard water may be softened by passing through a. Sodium Silicate b, Lime stone b. Ion exchange resign d . Sodahexa metaphosphate. xvii) Drum imemais ofboiier consists of a. Level switches for high/low level alanns b. Scrubber & cyclone separator. c. Hydrastep d. Downcomer. xix) The purpose of continuous blow down valve is a. to control water level b. to drain the boiler c. to maintain TDS d. to remove sludge. xx) Two gauge glasses often fitted in boiier drum because a. One is check against the other b. One is reserve c. It is a legal requirement d. To increase periods between naintenance

Q-2:-

Fiii in me blanks of followiIlg :(20X I)=20 i) The quantity of heat evolved when unit mass! volume of fuel is burnt completely is called

itL

ii). The minimum temperature at which fuel must be preheated so that it starts Jurning is called temperatUre. iii.) To remove the is the purpose ofa bottom blow down. iv.) At low pressure boiler. the water wall tube will overheat due to departure from nucleate boiling when circulation ratio drops to less th~ to__ , v.) Bomb calorimeter is used for determining the calorific value of & . vi) Anthracite posses calorific value and carbon percentage. vii) Temporary hardness in water can be removed by _ viii) pH of neutral water is __ ' ix) Formation of ice cube is the process where enrropy . x) Carnot cycle consists of two adiabatic & two reversible process. xi) Atmospheric air contains __ % of oxygen by volume. xii) Purest fonn of natural water is water. xiii) Calcium sulphate when present in boiler feed water causes the formation >f in the boiler. xiv) Analysis involving the estimating of C,H.N,S and ash is called malysis. xv) As per IBR 1950 regulation 29r ,the safety 'valve reset pressure should no: be less than __ % but not more than __ % below the safety valve set pressure tor safety '/alves having body bore more than 32 mm and! or having a set pressure above 2 bar gauge. xvi) Deaerator out let feed water dissolved oxygen is limited to >pb xvii) Cavitation occurs in pump at pipe Page-2

xviii) Ifthe oxygen % of flue ga:s in a boiler at Air preheater inlet is 3.50/0, the excess air is given to Boiler for combustion of fuel. xix) The mass in kg of22km; of any perfect gas at N.T.P. is equal to its molecular weight. xx) As per IDR 1950 regulation 391 A remnant life assessment test is to be caJ ried out for utilities and industrial boilers after they are operating for Hrs.
!

.'-'\ / j

Q-3:- .:- Use steam table for solving following questions. (5X4)=20 ./ i) Find the enthalpy and internal energy of lkg steam at pressure of 10 kgfJ,:m2 when dryness "- " fraction of steam is 0.75.

~I

t~~.<'" ii) and Findtemperature the enthalpy of230"C. and internal energy of 1 kg superheated steam at pressure of 10 kgflcm2 ;/ ~;.-'t Assume Sp Heat (Cp)i" 0.5 for this superheate<J_range.
d"} ~ . r"

'I (l-

;)

It:~.\iii) 0.005 m3 of ~ater is boil~ at 30C. It is heated ~ti,1 the pressure is 8 .kgflcm2 and dryness 0.9. Fmd the quantity of heat added for achlevmg above steam l}lL-illty. iv) A boiler supplies steam to a turbine at 18 kgflcm2 dry and saturated. From the same boiler st~l is foo by throttling to a steam engine working at 10 kgllcm L, Determ ine the quality of stearn entering to steam engine. Assume Cp for superheated range 0.5. v) If the superheated steam of temperature 200C at 10 kgllcm2 feeding to a SLeam engine and Specific enU'opy of this steam is 1.5&49 kcaVkg K. If 11lissteam in engine nxpands Adiabatically to 1.1 kgflcm2. Find the change of enthalpy of steam during expansion. Assume Cp for superheated range 0.5,

~J

'X
/'

-04 :- AnSWer in bricfany

offour:(5X4 )=20 i) What is priming and foaming process and state the reasons for occurrence I)fthis process. What are the measures for avoiding such process? ii) What are the main protection of boiler ? iii) State the causes of air pre-heater ftre and measures for preventing Air preheater fire. iv) What are the various boiler tube failure mechanism ? v) What are the reasons for PF mill firing and what action should be laken duting mill fire?

Q-5 :- Answer any oftwLJ :(IOX2) i) What are the tests to be carried out in various parts of water tube boilers o{:erating at a tem~rature uf 400C aJid above during Remnant life a.ssessment (RLA) of boiler as per IBR 1950 regulation 391 A ? List out all the tests in area wise of boiler pa.1s. ii) 'W1Jalare the requisile mounling,s,lillings and auxiliaries o[boiler as per IBR 1950 regulation 281? following operating data: \ ' iii) power plant of 62atM W (slngk ~yliJlI..lt:r turbinI';) is opcmlillg at full loau with "~. a, A steam Enthalpy of fe~d water Cl,;Ollomi~r inlet; 238 kl:aUkg, b. Enthalpy of final steam at Turbine inlet : 860 kcal/kg, c, Boiler Final Steam flow allurbine inlel : 250 T/Hr d. Efficiency: 85%_ Find the heat rate of plant and coal firing rate if GCY of firing coal is 3800kc1Vkg, ' ~ .--

_ '" '._'

',.' " .,'J

J ".'

';'y"~/

---------------------x-----------------

Page-3

..

~-:;;;:; ..
; ,,1,

__

'

;:-":;:;~"":':-~;:"~~~.;:;';

., ~H

"--',",~"--'.~ '-"'-~"""'

-'''"''"~---p::;;~~~--:F;F;>'''''';---=-_ .....

J.

Heverse adiabatic process i~knowl1 as'* (a) Iso ttermal process (b) Iso chorie process (c) Isent"oplc process (d) Nono of the above.

Orsat meter is used tor :(a) gravimetric analysis of flue gases (b) ~ volumetric analysi~of flue gases (c) mass flow of flue gases (d) measuring smoke density of flue gases

J9}-/ ppb oxygen (c) Is limited 7 ppm to :* r outlet FW 70 dissolve i1. Acid dew point is related to :.1 pr k:..
i O.

~D~ratc ~'_

(d)

1%

\ ()1')t:) \' pVVi PPb::.D'Do1XICOC

20. Proximate analysis offuel is determination of percentage of:(a) Carbon, hydrogen, nitrogen, sulphur, moisture ~Fixed ~arbon, ash, volatile matter, moisture (c) Higher calorific value (d) Lower calorific value.

,Ja}'Comsion
(c) Abra: lion
\2.

(b) (d)

Erosion:'

U) (-h W\",-t

None of the above ';.. -,. ()

!!b

3 Ts of cc mbustion are :. (a) Time Temperature 8. Tolerance

\~urbIJlenCe,

(c) Time Tolerence & Turbulence (d) NonE of the above. i3. Boiler water PH should be :(a) Less than 7.5 .~ Between
8.13 -

--

Temperature & Time

'If 1. Pour point of fuel is the :(a) Lowest temperature which oil will flow under set condition (b) Storage temperature (c) Temperature at which fuel is pumped through burners 9.2 22.
(e1)

tGmperature at which oil is transported

'v.(c) Morethan9.8
14.

(d) Stoichiometric quantity of air is the :-

None of the above

The safety valve on boiler drum compared to safety valve on superheater is set at :(8)

~ Air pi esent in the atmosphere at NTP conditions (b) Air re quired for compete combustion of fuel with no excess air (c) Air required to convert CO Into CO2 (d) Air required to form an explosive mixture.
15.

same valve

dO}" (d)

higher valve

(c) Lowervalve 23.

Tile capacity of induced draft fan compared to forced draft fan is(a) Same (c) Less \. {.bY' (d) More Less or more depending on size of boiler

Atmosph ~ric pressure at mean sea level is:-

(c)

lower/higher depending on stream flow

._,(a)
(c)
16.

l;~

Kgflcm2

(b) (d)

1.021<gf/cm2
O.9971<:gf/cm2

24.

The condition of steam in boiler drum is always:(a) Dry .~ (bY' Wet superheated (b\ ... ,_Jd)/ (d) All the above

1.0 t<gs/cm2

In isothermal process:(i)) \/011lI')'lP rE'rTlajn~ (:onc;tant (d) All of the above.

25.

Maximum energy loss in a boiler occurs due to :(a) " , UnhlJrnl carbon in ash (c) ash content Incomplete combustion flue gases

\, (n) 'Ter1"~ >erature remai!} cnnc;t::lnt

7t

(c) Pres: jure remCiin,sconstant

17.

Tile pres iura, at which latent heat of vaporization of water is zero, is :-

26.

The chief advantage of reheat cycle is :(a) Increase efficiency (b) Obtain more work (c) To decrease moisture in low pressure stages

(a) Below 1 ksc

(c)

(b)
(d)

1 l\sc
"'"

212 Lsc

225.61esc

10. Tile increase in pressure:-

(a) LOWHS the boiling point of a liquid _,(b) Rais ~sthe boiling point of a liquid (c) Incre ases Its volume (d) Nonn of these.

". (d) All the above , 27. T~e hardness of steel increases (a) Austenite

if

it contains :(c)

(b) Martensite

Pearlite ,(d) Cementite

:;-:--~

:-r--:,-::":'-',~.,-::

-,.:..,:.,.", ...;--.

:;;:;'-::';;:J:~~~~;~~'~~;:;;;-"",,,~,,,,,.~.~
""''''''';-'':r.;',~ffi'?":~,:-"=>"""",-"",,,=--=-,,,,",~.<;~~.,-'~''''''i'---'

.._-_ ...-,,;,,;;;;"-,~~.~---~
'-7"--" -7._-----::-T_:" ._~,..,..-~"

.... ---.--.

_-.._.,-.;;;;::;.:;" =~-,...".==..:c.;----: r.- ...

=' ....-.""'''''t:~,~,c~~ ..

Madhya Pradesh Boiler OperaUon Engineers Examination 2005

28. ~~.:_l% WhajJs the percentage of Sulphur (b) 3 found -7 % in most coals :(c) 5 -10%

Time: Q-1

3 HI'S

Boller & Hoat Engines

Max. Marks:

'100

(d)

8 -12%

riel< t11e correct answer:1. Three Elements of Drum level control are :.\.,. (a) Steam flow,~_ Feed flow and Drum level
....

(30 x1):::30

29. On throttling a real gas, temparature of the gas :"'If..

(a) Increases
(c) Remains same

Jl?}'
(d)

decreases
Depends upon initial temparature

30. The most efficient cycle is :-

(b). Drum level, Drum pressure, Steam flow (c) Drum level; Steam temperature. Boiler water temperature. (d) Current, Voltage and Power.

----

-~~-~--

-~----------------'

2 C 6~ r

~.a(
Q-2

Carnat cycle

(b) (d)

Rnkine cycle Diesel cycle

(1$x1)=15

(c) Otto cycle Fill In the blanks following:1. 2. 3.

,,: 2. '-IR 3.

Mill fineness for - 200 mesh should be :(b) 50% (c) '.' (a) 70% . The latent heat is supplied in Boiler at :'-p(a) Super heater (c) Re-heater (b) (d) ( N (b) . (d)'
.. IS
'L

30%

(d)

20%

:.: '."j ..

The condition of incomplete combustion is sensed by measuring ..... Heat value with products of combustion cooled down to initial condition Is called ..... Good combustion and high efficiency is indicated by high volume of

1;
4.

Down comer Water wall "14 ) Re-heat stearilline BFP suction line Cold end corrosion Flow of ash particle in boiler (, D .0 y oJ:\/v

In a Boiler hydrazine is fed at:(a) Main steam line (c) CEP suction line

4.
. t f~f 'I c_ ",,')-l~

~:'f..'t. ..... is the greatest factor in the corrosion of steel surfaces

in

.'

' .. j contact with water .

('Y( I
U. 7.h ~.

5.

Ash fuSlon temperature

Important f or:(b) (d)

is caused by the difference in densities from the difference in C(;L. {i)"~1H1 W~'\I.
\

=/ L)

the temperature of two vertical columns.

(a) Heat transfer in water wall. 6.

ci1\

6. 7. 8.
9.

Hydrazine dozing is done to .~~.'~\.t-Q.

Circulation ratio for industrial boilers is ..":.:..: Excess air required forcombustion is .... J:;:.;. !
It Is impossible

.' i '. ...

to a

(c), Slag formation Volatile matter limits :-

. (a) Maximum temperature in furnace (b) Maximum Mill outlet temparature

for the heat to flow from a body at lower temperature

'

'

I'

.. '

body at higher temperature without the aid of ...~

~.!.v ' ..'. I, , " '7.

(c) Air temperature to boiler (d) l"-loneof the above First law of thermodynamics is :(8,
Lc:;w of

10. No engine, working on a cyclic process is more efficient than ...........

engine when working between same temperatures.
11.

cons8rva~ioll cf mess

Petrol engine works in the principles of ... L.Li.; .. cycle.

12. 'The universal gas constant is .\.::~~;:: .. mkgflkgmole degree K.

13. In a balanced draught system ...1..1.... fan and ..d; ..... fan are provided.
14. In a very high pressure boilers forced circulation pumps are provided to

" (b) ~w of conservation of en~L_ (c) Law of conservation of momentum (d) None of the above.

~<2'l;7

circulate water through tubes as ........... Is low at high pressure for natural circulation. 15, Reheat cy.cle is emloyed in power stations to ~.~~~. and to ~ Ar.swer in true or false: -

8.

Dryness fraction represents :(a) % of mass of steam to mass of water (b) % of mass of water to mass of steam ,_ ,(0) % of mass of dry saturated steam to total mass of wet steam (d) None of the above. p.T.a.

(1-3

15x1 = 15

1.

Lignite has got lowest percentage of moisture than bituminous coal.

"

\;

2.

Efficiency

of heat engines is more than 80%. can never be zero. boiler is to be carried out

, 3.

Latent heat of evaporation

- _~_ .. 4
\

As per JSR, hydraulic test of newly constructed at

1.5 times

the design pressure.

,~ 5.

Hydrazine

is fed in CEP suction line_ the hardness of steels. with increase of temperature .

r
.'I(

6 7

.
.

Copper increases

Solubility ofTrisodium Compression Magnetite

in water reduces

:~ , 8. - 9.

ignition is used in petrol engines.

layer is found after deaerator.

\" 10.
~ 11. -\
\: "A" grade coal has lowest PHofneutalwaterlszero.

GCv.
C.

12. _;. 13. If grindability index of coal is less, the coal is easily grindable. Thermal power plant work in the principles of camot cycle. ~.>~.:.:'::,:-\.':':..-:.2--

PH -

-)7,

J ~v~-:rtulU> e
.L-i n ~

~5 ~ ""'--',

7 _
.-

b~.s.l C~ .:~c...;d..,

'.

, _l ,-

14. Turbine is provided

with multistage

blades

to limit the blade speed. range, the nozzle lIsed

15.
Q-4

For acceleration of fluid in supersonic must be divergent nozzle.

velocity

Give answers of the following :1. 2. 3. 4. 5. What is !nternal energy? What is regenerative What is the purpose air preheater? of primary air? difference permitted

10x1=10

What is the maximum metal temperature What is all volatile treatment in boiler?

in drum?

6. 7.
8_ 9.

What is the chemical composition of carbon steel?

What is the chemical composition of SA213T11 of SA213T22 What is the chem ical composition Effective disconnection

? ?
life of parts ?

of toiier?
of the remanent 5x2 = 10

iO.
Q-5

Ageing of Boilers - Assessment

Answer briefly any of

tile

five questicns-

1. 2. 3_
4. 5_ 6_

Define heat? What is the stress corrosion cracking? What is the purpose of drum in boiler?
Mention the type of safety valves us",d in boiler? What are the materiais boiier? Define latent heat 'I used iti sup,:::rhe2[er

and reneater

in modem

)";

'~:.,:)(

-t.-'

-- ------.----------. -------

... .-'i --.\

1 ',-,- I {- -'-', ..;... - ~---

,. \

r (' /

(, ~l

i")!

7.
Q-6 1.

What is dryness fraction?

4x5=20 Determine the cycte of power plant operating with foll9Wing condition :Coal flow Calorific value of coal Generator output 330 tons per hour, 3800 kcalJkg, 500 MW.

htsNer any of the four questions :-

2. 3.

Describe the commonly observed damage mech,misms that contribute to tube failures. A Steam power station of 200
'MMI

capacity uses- coal of calorific va!ue

4000 kcalikg. The thermal efficiency of the station is 36% and electric generation efficiency is 98%. Determine the coal r,cquired per hourwhen 4. plant working at full load. Find out the boiler efficieny of a boiler operating a: the condition below :Feed water temperature
Total heat of steam ( Feed water flaw

80 degree C
720 KcalJKg 100 tons per hou"

Coal flow
II"

20 tons per hour 3800 KcaVkg

Calorific value of coal used 5.

... ' -

!~U
~:I .. ~
rm ~'11 iR ,r.'.i.i~ .

Explain the processes involved in camot's engine. Ust the various components of boiler and theirfunction.

'

6.
VI ~

!~ ,'is:

r-Y k,;)).'"

xxxxxxxxxxxxx

l'~Ir----,,~. i
b~ '

f:i

I!:i/'~
1111

- .

/'

MADHYA PRADESH BOILER OPERATION ENGINEERS EXAMINATIO~J'"EB.2()()J BOILER AND HEAT ENGINES

Time: 3 Hours Nole- Answer

any fivc qUCS11()ns ()lIcstion no.

::;arc

cOlT1pllls\lI\

0.1

Tich: the COITcct ans\':cr

(i)

- I 'x 20
IS

First

law of Law Law Law None

thermodynamics of cOllser\'<ltion of Conservation of Conservation of the above.

of mass of energy of momentum

d.

(ii)

//
d.

Dryness fraction represents. % of mass steam % of mass of water to tomass mass of ofwater. steam. None of the ofabo\e a. % of mass of steam to total mass of steam - water mixture.

~.

(i i i) ./ a. (a)

b.

d.

ISO thenna] process . steam/water 275 325 190 Kse Ksc Non of{b( the above. choric process. ISO Reverse abiabatic process are known The critical pressure J 225 Kscfor (c) Isentropic process.

as IS

(i v)

(v)

Maximum

allowable

temperature

gain

111

Economiser

is (Recommended

value.)

(3) (d)
(vi) AFT (3) / stands Ash Ash . None for flow fusion tunnels. tc'mrerature.
11,)\\'
&:.

(c)

IIO"C

-4b)
(e) (d)

Allowahle

tcmpGfatufc.:.

of thL' ~lhovc.

(;1) (11),

111\llJc

IU1ILkc'

\l'} ~)LlI
\d)"

Side

lurnaC'L" c't' the ~Il'l)\C

On \\,Ill'1 \'..lli

NOlle

; ! .,.

1~

iitlr
:Idll~ I~ .'j .. j'd~
Ii: ..... '

ii~' '.

il.

lH~II l!ilfl :1

--,.

II 03 II

Boiler water I'll should be Less than 8

~
(c) (d)

[3etween X.S - 9.2 More than 9.6

None 0 r the above power pfant-

With feed water heating, Cycle efficiency of the themlal / (:\vi) ~lncrcascs (b) Not changes. (c) \ncrcase or Decrease (d) None of the above.
In suction

/(xvii) (a) (b) (c) (d) (xviii)

:ypc mi\\s P A fan is located-

v After

Before mil\. mill. ,/Between RAH & FD Fan. None of the above chamber provided in BF? balances-

Balancing /(a) (b) (c) (d)

.J Axial thrust
Radial thrust Peripheral thrust None oftne above
to Stearn Boiler is called as-

\xix)

The law related

(a)
-fblJ

lBA
lBA

\929
1923 \949 1950

(c) (d) \ xx)

lBA

lEA

Boiler Farameter~ are expressed by (3) lb)

. (el, T/\1r. of steam produced O(

Pressure Kg/Cm:
.

:J

i ct)'

Outlet Tcmf1 is -\ \ 1 of the above

BOILERS ~~~e :

AND IlEJ\'l'

I':NGI~I-;~

J Hours
&

Maxiluum Marko :: 100

. "_.0 __. '

-..t-

vv

'.,

________________________________________________

"flY

f,,"r'

nf

~'nlnln~.

~(:)

Each question carry e4u~1 mark~.

a~'
!"

,~

'~:

Q.1
A.
<;:_ ~
l7 (T)

Ill:'

L'

Ii: )

velocity
steem

of
are of runq~

~;n t-."

I'"

t- ,:--d

t. '" .,n,

.' nd

k. <-<

superheated

in pipes

8 -) [\

meter/sec

und

(fj..7...;..lr_:1 0

meter/see pipes

respcC"tively. specifiC'~tions
tZ52cSs
~5
j)J~
_

B.

For Carbon Steel

OIN cod.;!
ilrc

p<:"r

1~:2(.js ':.: /1 .1~.{

6-

j ~'!~~

IS:
respect.ivel'y'.

R 1

c.

Carbon

Steel "C.

temp.

"r
be

D.

The

volatile

lTIu t: er

present

.in

the:

coal

tOay

combustibles

gases

ns

.. :, .,l'f.... . \ 3 (~.l.,.
E.

and
and Grindibility

or. un c:oml:)ln;tih1l0~

(J''1~'':'

I ikn

of standDrd

coal

is
a ir

ctefindcd

~s
l2.S

a:1d grindibil
to formula.

i ty

of

commerc

i.~::'::

.1 Vi,

,i

from

__ C_:' from

Excess

is

de term ined

the

...

,' .

'i'h"

mi1X.U:1UIlI

'.

cCGrJomi::cr

0ut.lc:L

L ',--'.

t~:l11p. i~', u~;u(111y

m,:lintdincd

"C bel ()\I t. h (~ sat urat ion

Clnd

tE:i11fl. to

prevent

H.

The re:noval

of

Y<.1se.> is
"C

i.1cclJfT'.f?-'-ish,-.l1

llY

heating

the

feed the

\:ater to
eCiu pmc n

'.-lith

~uuseqU(;rlt
_

Ci'ji.tClti ..f1 in

Cull ed __ i_.\~'_'.-,l_-_,
safety
attachfuents

T.

Deaerator

Q~e

,,-

,/'

(i v)
( v)

__ L\..."CI

G
L.!.
(-\,. I.
.
."\.

\ vi)

~~

..

.J.:.::-.L..--_'

./1...,

\.

,j

. ~ ,0' '--- o. (,

"

__

I/

t. f. .

J.

'I
Steam Turbine continuous blade

,.rQ"1\".

mat~r1al

1.~N(:fN";::'; 15 '~f..,:1 I

,,? vV':>,"-,1. L' ,~.'~----.

,-

Condensing '!'urbine
L.
Steam temp.

low load

exhaust

etOQIU temp. ope~ation. duri Clod

n'.J

f.../l,.

t) ~ ~ C

dm:ing
in for

",C

,2,'/. (,

,'" ('~-T'v....

throt l:l inlJ process f..~j-n.{ ". used

"v .t~ equipment reduct (".~rvI~ on. pressure

)">,-1'. ~~,.).",

M. N.

Condensor

in

Power

Plant

decreasing
AFBC Boiler CI:"'BC Boiler
~.

the exhaust
~

h ('''!'l. .p4L eft iele.'.j by 1". :;:illrl~ of 5l'C.llll hl'low OItmospher.e.

combustion range of
u (/

and has it is L-;lin Uf. he of coal feeding

effi,;iency than ft" to_ ~~ in AFBC/CFBC is

o.
P.

Major

types

systemvailable

Boilers
f

are

v\.-.l.'-f-.17

and
of eFEC

Major attractive feature (." r ,"./-;,,t.1 Sf f ;;../1->' Since heat release as 10\'" as capacity of a AFDC

i\ . ./\ .... r-Boiler

d '... rw.r.f~ emission

Q.

TPH.

rate per unit furnace cross sec~ion is ' hence the max i.11111~1 econOlFica 1 Boiler get r.estricted t.o ._ to velocity under ~o and e<1sy control of heat response of a cpnc Boiler

R.

A
to varying

fluidiz'
load.

ab-s-o-r-p-t-i-o-n--a-llo\v5

s.

Hardness of steel mClY be de find as static & dynamic loads and also as resistance

and

T.

Steel t(lay be simlpy defined which does not contain more short notes on

as an allow than

of iroll and carbon Ll % carbon. 20

Q.2

Write

(1)

(Hi (iii)
(iv) (v)

What ~s energy. Wnat is circulut~on What are different

rdtio
mode

~
of heat transfe__ c__ '_' in _ on
ESP

? What is the purpose of deaerator \'Jhat is the effect of sulphure performance.

Why rotor heating is done in turbine

c:>al

(vi) (vii)-

?
I"

Why chlorine

is added

in cooling

W<1t01' ..

i<..,

(viii) \-lhatis the critical Fressure of \'latcr '_ :.=.:.C-=," (ix) Name different type of governing in ste~la tuchinc ? (x) Which cycle has maximum thermodynamic ? between two given reservoir ht what pressure c~!!ied out after ,>]hat de- you ~tre55 of e~cess 6f co~l
0i~

efficlency

workiny is

(xi)
(xii) (xiv) (xv)
;i. .

tbe hydraulic te.:t of erection on site ?

i3

nailer

mewn

by Ilel

of

c.~(ul ~~pt in boiler

(xiii) Why

What is normally percentage ? for efficient combustion What is proximate analysis

(x'vi)

is thE limit. of dissovh; (:':':Y'J"n in FW aEtel:" (2:) '007 ppn,:: p ph deaerator'? (xvii) What".is motcrial for Superheater (most commonly used) -:'

\yhat

{xviii)l-Jhat
(xix) (xx) vinat \";hi'lt

is
is

the
?

normal
c'

limit

cor

BoilCc:1"

UL'Uln

lcv.d-lo\v

protection

3 elEment

.is forced

circulation' P.T.O.

-3-

(T\')

}l'f)J1Clwi.ng

Boiler:
Quantity

di"lt",a
of coal

worl:'

r.n]1.p~l;;ed

clllrinq

"

tP.H':

"T'

;:!

Rt~am

12

ii iil
iv.

burnt:

750 kgs/hour. kgs/hour.

Feed waier

5upplierl

~ 7000

CoV. of coal
Feed water

fired

. 8100 kcnl/kg.
at economizer inlet 25C.

temp.

v
vi vii

Feed water temp. at

Stearn pressure DrynesS

economizer

outlet'

BOC.

= 10kgf/cm2.
of steam
leaving

fraction

leaving

boiler drum 2S0"C.

= 0.95

viii Temp. Determine

of 5tc~m

superheater

(a)

Thermal efficiency

of plant.

(b)

Calculate
components

the

hua

absorbed

by

fC0d

Wil tor

in va r.1.011S h.. =181.1

of boiler

as

of

total

heat

ab~orbed.

From steam
kcal/kg, (a)
1 Kg

tables

3t

lOkgf/cm2
Cp==O.5

t,

"l79v06C,

L=482 Kcal/kg.

kCill/kg"oC

of coal on burniny gives BOOO Kcal of ton heot. of Oet,ermine the di.stcII,ce a lc,comotivcc;'rl yo on for

coal

burnt
is

if

10't,

of

h.~il

re 1CCl F;cd
weight

\Vork.

The' of

by

the tractive

COil

is effoct
The 8 20

required
weight

5kyf/ton
is

dead 2~OO

locomotiv~.

of lccc~ctiv(~
notes on :

TortS.

0.. 4

Write (a)

short

NDT of components.

lb)
(cl

Advbntage Effect

of pulvcri~~tiun. on heat rate.

of vaccum

(d)
(e)

Role

of

alloying
acid

elE~ment
(fMA) acid

irl

high

tCIIlEJ

~;t(~el.

Free mineral Equivalent

(f) (g) (h)

mineral

lEMA).

Boiler safety i:lterlocks system Fluidi7sl.' bed combu:;t'..on s,/o::tem.

Steam Turbine cold
:;t~lrtur

'Iith

!,\('Lt.?d

diagram.

(i)

to
cIS

synChT"Oll i

:.i !\IJ. codes. procedure and

l?es idua 1
Cl

lj}
Q . 5
f!

Furnace

oil

specific':'I._l.On

various "\'lrite Describe tht:= :.RU'.) 0: 'sr?ecific aspect

t.ests
be

with

!,Jcr

executioll
dUI

I~;-I'J')j-\~71

sessment". ignific ?i\\:

to

conducted plant

i..n(J

Life 20

its

, ':''llll tion .

Ci:llI;;eS'

Resp('l,:', 20

Acti.on

for

the [ollo' .. Jin'J

fire

Pli1nt

:\bnocrnal i.,:ll.::;.

i
11
iv v

Air ~re-heater

Slag in the water ~alls

Condenser Clinker

tube

fil~lll['e.

formation

.. Il AFTIe/CFee

boiler.

/oU\.D!O:'}\ PRADESH

BOILER

OPERA'I'ION

l':NGnn;l.;HS

EXl\MINi\'l'TON

,JULY

7.~~QQ

me: 3.00 Hours

BOILERS

& HEAT ENGINES

Max.Marks

100

te:- Answer any Five question, No,l carry equal marks), 1 Pick up the mo&t each question. correct answer

is

compulsory.

All

questions

from

the four

options

against

1.

On throttling:d real gas through a porous plug, temperature of gaa-' , (b) Decreases (a) I'ooreases (c) Remains same (d) Depends on initial temperature Frictional heating inside an insulated (a<, Reversible adiaba tic Proces 8 ...#B1' Irreversible adiabatic Procoss, (c) Isothermal Process. (d) Isenthalpic Process. Value of Joules units is.(4) 4.18 \c) 22.4 Nechaniccll Ollul valero t chamber is-

2.

3,

of
x

hei:lt; in

S.l,

(d)

(b)

6.023

1023

~.

Head developed by a pump depends on(a) Density of-fluid (b) Temperature pi fluid (cJ Speed of the pump ~d) All of the above. TlJrbine exhaust--condenser is operating at '50 nun Hg abs, on 'steam side and 0.5 atg on water side. AS per I.B.R. Condenser tubes are to be subJected to a hydraulic test pressure of-' "'" ,._ (a) 100 mm Hg abs. (b) 1 ~tg
,( c)
2

5.

i'

-0.

Kg/Cm2

(d)

70 Kg/Cm2

6.

In a 'vertical water tube natural circulation Boiler, water in bottom headers 1s~ Saturated (b) Super Sdturated (c) Sub cooldd (d) Super heated. Hydcazine doeing to feed water residuathyd~azine asis controlled
0.04 ppm

7.

by monitoring

Ja)
c) 8. for (a) (b) (c)

0.02

ppm

(b)

2 ppm

(d) None of the above. factor Use factor Load factor factor = 1

Thermal Power PlantCapacity factor = Load factor X Use Load facdtor ; Capacity factor X Use factor ; Capacity factor X \d) Load factor X Capacity Factor X Use

9.

T QK ; Average temperature of Chimney Gases Tl OK = Atmospheric air temperature. = Kg of Air Per Kg of fuel W K r = Draft in terms of gas column H g Height of Chimney Condition for maximum discharge through Chimney is(a) T = 2Tl (W+l)/W (b) H = H 1 \c) Both (a) & (b) (d) None of the above. . Useful heating value of coal is(b) Lower heating value (a) Higher heating value (e) Calorific value X Boiler Efficiency (d) None of the above.

10.

Con td. , .2

ctfi.-

Ratio of Primary air to Secondary air flow (c ) 1 ; 3 (d) 1: 4. ( a) 1: 2 \b r--2 :l (5) The Ratio of Primary air velocity (a) 1 (b) les8 than 1 (c) More Mill fineness for - 200 mesh

is-

to Secondary air isthan 1 (d) Any value. be -

(6)

should

(a) 70%
(7 )

(b) 50'

(c) 30'

(d) 20%
in (d) Rehea;er. to-

The latent~heat \.~)/waterwall

is su~p1ied (b~ Superheater

in a Boiler

(e) Down comer

(8 )

In natural circulation the driving force is due (a) Force exerted by Drum pres lure , .' .,(j;yPOensity"difference ot Steam and"wa'ter (c) Pressure of BFP (d) None of the above. In a boiler Hydrazene (a) Main steam line (c) CEP Suction line

(9)

is fed in (b) Reheat Steam line ~dr BF? Suction line. (d)

rature

275 Ksc. 325 Ksc (d) .-;' \c) The (a) 50C (b). 100C (c) (10) Pressure for Ste~ater iala) critical 190 Ksc 2~5 110C Ksp rise in Econ~miser is-

JOoC

'(12) Ash fusion temperature is important for(a) Heat transfer in water wall (b) Cold end corrosion ~siag formation (d) Flow at ash particle in Boiler. (13) The- maincomoosi tion of Ash .. SealEil is form~c1,,_ :,,-_,__ , Li) Iiislde'thetube --- .. --- (b) Outside--the tube (e) /' On the furnace ~efr~=~tr~ (d) None "bE the ~bove.
"

c'

14.
i

Control stage in the turbine is (a) Last stage (b) First stage (e) One atage before last state (d) None. Pent house i~ situated (a) At the top of boiler (e) Below drum Down comer is(a) Inside furnace (e) On water wall surface The value of pressure \a) Higher \c) Equal setting

I.

':
"

15. I. 16.

(b) At the bottom ~f boiler (d) ,None of the above. ~b)/~tside furnace (d) None of the above. of MS Safety valve is donat(.b-r-Lower (d) None of the above.

.:

17.

18.

Three element control is used for(a) Spray control ~Drum (e) RH steam temperature control (d) SF? Recirculation control. The Boiler efficiency in the range ofin Modern
80%

level

control

19.

Thermal
90%

Power
(

Station
40%

is

(a)
20.

60

b)

,tc')"

d )

Volatile matter limits(a) Maximum temperature in furnace. (b) Maximum Mill outlet temperature \c) Air temperature to Boiler (d) None of the above .

. ----.--

EXAMINATION

MAI\CII-l':J':J.J

"\uximum

Mur~:;

: 100

'rtme

: 3 Hours
'BOIL~n5 AN 0

------------Note Answer carded

II EAT

-from

ENe. IN t::S

The any
()

n'ark~

QUQstion NO,l and \)~I e,'.!c\) 'I U l S l L0 11

in

(our

o(

the
,~ t

renlaining,
C 1\

quc~tlCI1~, the

r c:

L11 cJ I c<1I: c: (\

the

0 (

0.1

Pic k u P the quC!sti011 (i)

0 s t co rr e c tan

sw c r

the

(our

opti,)nS

o(jainst

each (20)

Th,'} latell'.
(a)
(" l,.' reill

heat
~l.llS

of steam
SQ!'1IL:

vlitr

increase

of pl,~~sure

inCL8aSC5

~l (d (ii)

decreases none of Clbove cyde, din part of the sL(lam hi! at i n g the : ls V/ithdrav1n

.In :h~ rl'generati'/o 'r0m the l u r bin e

&

USe

~
(c)

(d) liit)
,.

exhaust fan foed water steam being supplled all of the above anal.ysis uf

to the

turbine

The \lLtimi'te perc~ntage :

coal

is

done

to as:1

determine

the

~ tb)
(c) (d)

c';-rbon, hydFlgen, nitrogen, higher calori,fic vL'Je lower calorific value fix.,-:l carbon, ash, vol~tlle

:.:-.llphur,

matter,

moisture air h =a tor

(i v)

'.'I'h: ::~l ':.';'\('~l the

(:l11e'\'Iin ~ i~ I.ct d regenerative

11

.";'J '-J s t rom t, Y I) <, air dipnel1yl air heat'er TLlbdar air r,eClter ?cbble h,eater.
l v 1

eat c r

'rl1o

f'

l.iliC<H ant 1 r~ r. t r 0 S t <;\ tL c

stops
i>'
<:

il'\

tho
II

procGlSS

or

pralcipltation

in

the

L p 1 tat 0 r

ra

l. 2.

3.
4. The
(a) (b)
(c)

lonisation of LJislodqing of Il\igration of D<:,<.IOSltion of correct

1 .2,3.4. 1.3.2, ,4

gases & charging of dllst ,particles. particles from the coll\lcting 5urfa-::e. particles to the collectol. em th~ collecting surface. dust p.3.rtlcles o( dl((erent steps is :

sequence

4,3,2.
1 .3.4

I
, '2

(d)
(v L)
1\

(.1r ,l\.\CJ h l

i~', pro

d II

cad

1'\

a b,.,

i'. cr

(a) (b) (c ) (d)

to to
t \)

"J

o'lide adequate 5UPl)ly liir [0:." l:'E' fuel cornbustion. 'ischiHge the gases ex h a \l s t the gas e 5 0 f com b \.l S t i 0 r, f r 0 m t h l: r.0n,l:iu s t ion the a!)Qve. (ContcJ .. 2)

ch?\:nber.

.;Ill)(

i~
i!l
"

,I

f:!lr
.

,,(-

, .,,: 'I',

..

3 ..

xv)

The

three

'T'S

f.or good

combustl.on

ale

,'{.a0empl'rature, tim~ e. turbulanee tll) tot'~ ail:, true f.uel & turbulanee tc) th'otoUS;h mb:l.ng, total air & temperdtur~, t\ n'e 8. t e mper a t u r e , ( r' ' tot 0.1 a.

i"

(xvi)

l!"r.omplete

com'o\Jsllon

can

be bc',:

juo'.lod

by

smoKey chimney exit excess 'r in flue gases measuring e,' rbo" mono-oxlde 1n flue measuring oxygen 1n flue gases, (xvii) Natural & with water circulation by convection iocrea,,'. '\n pressure of boiler: incre/lser. decreases remains unaffected first increases & I:.hen decreases in

9 llse::;

water

tube

boller:;

(u) (b) tc) .. ~d) ('.Lx) The

:ombu.st1on e[(\.e10ncy leaKage oC air into boiler ultimate analysi" of fuel analysin~ the fluJ ga~ on commonly
\1S'l ~

tho

SpClt In steam turbInes ts

mer.hod

oC goVeL nin:j

b~
(a) U-0-1/ (c) thro t tle go" e rnin (d nozzle cont~ol governin0 ~ypass gov"rn1ng hydraulic ~overning ooLnt i~ Lho to wl.ieh oil' ,litnimum temperature vapour:; i.n 'jive o~[ In(lam",bl.e when brought "gQHe monlentarlly :'lame. tcmpratut'e al whteh It ;,oUdUle" it catche:; lire w\.thout e>:ternal none o( the OIbr)'Ie (T,ajor
'II J.th

~)\
(xx)
POUl' (a)

oC !'uel

oIl

is heated \.n order sl\fflcl.pnt quantity in contact with

to
'<')

(\)) (c) td) Q.2

or

coguals pede rmance (5)

aid

List out assocl.ated ~Hll

wh<"t

ciH ferentinl
\'Illl. har
8

factors affecting mil1.ng plant the nature of coal handled. Ugh. WhOlt i;1cti,c;n will you i:; it is allowed tu c'mt~.!lUC ?
'::n
If

take

Vihat ld)
j :!J

is

(urnacp.

expl.osion between

7 \?rimary a Air
&

Vlhat

.\5 dl([eren~p.

Secondary authori A.r, ;ing

i~
\~

(5) ,the (5)

What

'1!!1
i"

: .~;

0,3

la)

Enu.merate condition in which J" to be renewed use of Boiler

HI?

certificate (5)

\b)

heRter" on the eUect ~t \'1\.11 have

turbine on the

sl.de boller

have bp.en bypassed. ;Jarameters ?

..

5 .
(5)

a.8

(a)

Cdine

equi.valent

evaporati'jn were

(rom taken

and

at

100C. a test on
750

Foltowing
Lloilcr.

observations

dudng

steam (15)
K~.
V.

Ouality

of

L'

~l

burnt

per

Iiour

,'r C.V. of coal fired water "u(er

IIf1ur

7000 8100

I) ,

KC<.ll/Kg.

Temp. of feed Temp.of feed

entering leaviny

eeonomiser
uOOC

economiser
10 Kgf/Cm2 0.97

Ste<!.m Pressure Dryness fraction BoUer Drum Terr.p.

"

c f

steam

leaving

of sttam

leaving

super

heatet'

Determine the thermi.) efficiency of thr. plant. else calculate the l~ca\: absorbed by (eee. water i', various components as a percentage cf the total heat absorbed. from
at hfg

steam

table
ts Keal/Kg.

10 Kgf/Cm"'" : 462.1

hf

:: 181. 2 Kea l/Ies... ,

hsuP

702.

I.

Kcal/K g.

It .

. 1 ",l

.......

....

"

.. " ... '

".', ;.~
"

..,

: .. '

.
.. 2)

:Cantd

C.D --

-.

!~''7--".

;<ADBYII PRA[.",;S BOILEROPFPATION~I_'

BOI:LERS

S ElU\M1I1AUOR. MAY 2002

Mit,xim'wu Harks : 100

AND BEAT tmGINES

Note:

Answer Each

que~tion'No. carry

1 & any four of rem~inin~.

equal (each marks. 1iub-s~ction carries 1 mark..) ,steam meter/see and and

q~estion up
>:.he

Q.1

Fill

blanks

20

General superheated

velocity

of'

dry

and

saturatEd

steam in pipes

are of 'range

meter/secrespectiv~lyy B. Fo: Carbon Steel pipes specifications ~ '3 and pipes are C. used for a ma~imum I?er

IS,

BS and

DIN code C. Carbon

are Ste~l

r'C!npectively. temp. of

D.

volatile

matter

present

in

~he'

coal

may

be

cc:,\a.lstiblesgases

as
ga~es like

and
ane. E.

:-------i

-'
coal is derindF.f} as coal vatles air
Sl'h~

or un combustibles

GrL1-.iibility

of

standard

';\M~ co<\\

and ':jrindibility

of commercial
Excess

from

-~---<60
from

tp.
formula. F. Excess The air

:.I'-.'~'-'.. ' .-'- .~-.-..,..-__ ...

is

determined

the

w~ economizer ~

--r~,--rl'\1:1

G.
\

maximum

out+et

temp. C

is

ulJu'ally

rnaintE..lined

to

belo,,, th,e 'saturation

temfl--to prevent

anj
gases is accomplished by heat .. ing the fe.ed the

H.

The

rem~.val of

wa.ter to
;~~~ipment called
I. Deaerator safety
Tem{>

C wi';:hsubsequent, ag,it:ation in

-+-0
attachments
~~~
I

are

(i )
(ii)
(iii) (iv) (v)
(

~Y.~,
<::A~~,\j ~,,\ \{
\ {> >-II? \

1.""cl.-.'c oJ-ov .__

..~,

~~?S,,",

\-\~~, o~

.... --'--"--"-.-.~.... - ~--.- ------.-~~------..c---....

~ ..'

.,'

.@ -2

-.

.""/, L~-',

J.
K. L.

.. : ,';~~\ .",;;,.~~>,~ &...

Steam Turbine blade material congens :ng Turbine eX,haust stearn temp. continuous low load operation.

i. __--'-

~
~.

-\.,~
di',d.ng\ in for

',"~.'\.

Stearn temp. duri~g tr.:ottlin9 pro~ess equipment . and used pressur-::! -r-e-d-u-c-t-i-o-n-.---- ._. -----

M. N.

by Condensor in Power Plant efficiency decreasing the exha~st pressure of s~eam below atrnospheDei CFae Boiler has . combust.ion efficiencytha'n AFBC Railer and it .is in the ,range elf .'_ to % .

o.
'",:>"

---~------Major types of coal Boilel3 are

feeding system available in AFBC;Cl"BC and'

P. Q.

Major attractive feature

9f

CFBC Beiler w.r.f. emission

is

since heat release rate per unit urnace cross section is as 10' as henc the m:;\xi:uum economical -l-e-r--g-et res .:r icted tc .t 0 capa c y of-a--A-F-B-C--B-o-~-' . TPH.

~.":"

i.. ;'': , .
,

:~f>,
.

ve~6c~~~- and easy control of'heat flui . .dizing . ,~ab~orpt on al10~~_ ,. :,' . ,respoi1se,'ofaCFBC Boiler 't,ov-ary n'g 10adXfA'.'_' '_"_.'_'.

i: ----,-

'.

~.

,"

~.

s.
T.

Hardnes; - of .steel
6tatict

dynamic loads ~nd als. as resistance to and

be-

def .nd '

------

as_

Steel<l\\a. be simlpy defined a j an allow of iron and carbon .% carbon which doe not contain more ~aan

Q.2
.... ':.'-_:~:""~-rc :'

Write short not,s on

'.----'

. :.~ ..

(i) ',' : What'. is e\ersy. ,., .. _,.._.-'.-::::.:.--~.,----.::..' " ," '-_--_":""~~~ __ -'..:c,--'-::.~"-':::-:-{i-I-)' i~b.i:ftis c.. 'culation ratio ?
!

of heat transfer ? (iii) What are dl':,ferentmode , f \ (iv) What is the )~rp06e of deaerator ? ( v) What is th performance .

offc,,',

of

Bulphurp

In

coal

on

ESP

(}Ii) Why rotor heat ',ngis lone in turbine ? (vii) Why chlorine added in cooling water? (viii) What is the cr; :ical)ressure of water ?

il

(ix) Name different ~I?e

(x)

of governing in steam turbine ~

(xi)
(xii)

Which cycle ha maximum thermodynamic efficiency workin~ betwe~n two ~i~'~n reservoir 1 At what press' re 'the hydraulic tes tof _ a Boiler i~ carried out af". U' erection on Bite ? I What do you me; .1 by HGI. of coal ?

(xiii) Why stres6re:~eving is required for steam headers? (xiv) What is normall percentage of excess air kept in boile for efficient , mbustion ? (xv) (xvi) What is proxim~ ,mit Wh3t is the de':lerator ?
,...41

~oal ?
oxy,ge;1

of

dissovle

in

FW

afd
~

(xvii) What is materia'

for Superheater

(mo3t commonly
-_ ..~-

used)
'- ,.,,1_'

2
".

3.

a)

Draw a neat schematic layout of Demineraliser Plant 8.

explain the working.

10
10

b)

Explain with neat sketches:

i)

ii) 4.
a)

Boiler Safety Valve Steam Trap

Draw a neat sketch of Raymond Bowl Mill & explain the INOrkingof all components. i) Draw a schematic layout of Oeaerator, Boiler Feed Pump & High Pressure Feed. Water HeatE'lfs.
with feed vvater heaters.

10

b)

5 5

ii)

Explain how cycle effiCiency improves

5.

a)

Estimate suitable size for a steam pife to carry 140 Kg/Sec. of steam at 100. Kg/em pressure at Assume a steam velocity of 50 metre/second.
i

400ClC

..4"

i\

dl~ _
-

b) c)

Write a note on Soot Blower Write a detail note on annllJal overhaul of boiler & explain in details the inspections & testing to be carried out.
I

5
10
20

6.
. Explain the working of the fOI~Owing : i)

ii)
iii)

iv)
(:.~;~~'4'"

'Nater Sbftenirig Plant Mechanical & Chemical Deaeration 3 Element Drum Level Control Automatic Combustion Control of the Boiler

~i:: ~
~~;J~

~}.,.

\'