Paper 2 Set A Key

Regn No: _________________

Name: ___________________
(To be written by the candidate)
12
th
NATIONAL CERTIFICATION EXAMINATION
FOR
ENERGY MANAGERS & ENERGY AUDITORS Ot!"er# 2$11
PAPER 2% E&er'y E(())e&y )& Ther*a+ Ut)+)t)e,
Date% 1-.1$.2$11 T)*)&',% 1/%$$ 0 11%$$ 2RS D3rat)!&% 4 2RS Ma5. Mar6,% 1-$
Set)!& 0 I% O78ECTI9E TYPE Mar6,% -$ 5 1 : -$
(i) Answer all -$ questions
(ii) Each question carries !&e mark
(iii) Please hatch the aroriate o!al in the "#R answer sheet with $lack Pen or %$
encil& as er instructions
'( The density o) a substance relati!e to water is called
a) !iscosity b) seci)ic gra!ity c) dew oint d) our oint
*( +hich o) the )ollowing is not a unit o) !iscosity
a) Engler b) Rankine c) ,aybolt d) Redwood
-( The amount o) heat required to raise the temerature o) ' kg o) a substance by '
o
. is
called
a) sensible heat b) latent heat c) seci)ic heat d) net calori)ic !alue
/( +hich among the )ollowing )uels is likely to contain ma0imum ercentage o) sulhur1
a) kerosene b) diesel oil c) 2,%, d) )urnace oil

3( +hich o) the )ollowing grades o) 4ndian coal will ha!e the highest calori)ic !alue1
a) $ b) 5 c) A d) E
6( +hich o) the )ollowing is not measured in ro0imate analysis1
a) !olatile matter b) )i0ed carbon c) sulhur d) ash
7( +hich o) the )ollowing is not measured in the ultimate analysis o) a )uel 1
'
_______________________
$ureau o) Energy E))iciency
Paper 2 Set A Key
a) o0ygen b) )i0ed carbon c) sulhur d) nitrogen
8( .aret loss is associated with
a) combustion o) coal b) storage o) coal c) combustion o) oil d) storage o) natural gas
9( +hich o) the )ollowing is not true with resect to imroer si:ing o) coal
a) results in oor combustion b) lower e0cess air resulting in lesser stack loss
c) increase o) unburnts in ash d) lower thermal e))iciency
';( +hich o) the )ollowing )uel constituents releases ma0imum amount o) heat er kg during
combustion 1
a) hydrogen b) carbon c) sulhur d) nitrogen
''( +hich is the statement that is true o) a )ire tube boiler
a) has a single steam drum b) )ire is in the tubes
c) water in the tubes d) has multile steam drums
'*( .oal is not burnt in susension in
a) )luidised bed boiler b) chain<grate boler
c) sreader stoker boiler d) ul!erised )uel )ired boiler
'-( +hich o) the )ollowing is considered in the calculation o) =E!aoration ratio>1
a) calori)ic !alue o) )uel b) latent heat o) steam c) )uel quantity d) all o) the abo!e
'/( +hen solutions o) di))ering concentrations are searated by a semi<ermeable membrane&
water )rom less concentrated solution asses through the membrane to dilute the liquid o)
high concentration( This is called
a) re!erse osmosis b) ion e0change c) so)tening d) osmosis
'3( 5lash steam can be reco!ered )rom
a) suerheated steam b) saturated steam
c) high ressure condensate d) condensate at atmosheric ressure

'6( +hich o) these is not true o) =critical oint> o) steam?water mi0ture 1
a) the temerature at critical oint is -7/('3
o
.
b) the ressure at critical oint is **'(* bar
c) saturated liquid and saturated !aour lines meet at critical oint
d) enthaly o) e!aoration is ma0imum at critical oint
'7( The head loss due to )riction in a ie is
a) directly roortional to the diameter b) directly roortional to the gra!itational constant
c) in!ersely roortional to the !elocity d) directly roortional to the square o) !elocity
*
_______________________
$ureau o) Energy E))iciency
Paper 2 Set A Key
'8( ,elect the wrong statement with resect to steam tras
a) discharges condensate as soon as it is )ormed
b) does not allow steam to escae
c) caable o) discharging air and other incondensable gases
d) does not allow condensate to escae
'9( %eat trans)er in a )urnace is e))ected by
a) radiation )rom )lame b) radiation )rom )urnace walls
c) con!ection due to mo!ement o) hot gases o!er the stock d) all o) the abo!e
*;( 4n a coke )ired cuola& carbon mono0ide is roduced in the
a) reheating :one b) reducing :one
c) combustion :one d) melting :one
*'( 4n an oil )ired heat treatment )urnace which o) the )ollowing is not required to determine its
e))iciency by direct method
a) weight o) inut material b) o0ygen ercentage in )lue gas
c) )uel consumtion d) calori)ic !alue o) )uel
**( +hich o) the )ollowing may not hel in energy e))icient )urnace oeration1
a) maintaining a ositi!e dra)t inside the )urnace
b) minimi:ing re)ractory losses
c) comlete combustion with ma0imum e0cess air
d) use o) ceramic )ibre in batch tye )urnace
*-( ,elect the wrong statement with resect to )urnace oerations
a) the burner )lame should not touch the stock
b) air in)iltration leads to o0idation o) billets
c) ceramic )ibre linings are used in the e0terior o) the )urnace
d) heat loss through oenings is roortional to T
/

*/( The e))ecti!eness o) a heat e0changer does not deend on
a) seci)ic heat o) hot )luid b) 4nlet temerature o) hot )luid
c) 2#T@ d) 4nlet temerature o) cold )luid
-
_______________________
$ureau o) Energy E))iciency
Paper 2 Set A Key
*3( Pinch analysis uses the _____ law o) thermodynamics
a) 5irst b) ,econd c)Third d) $oth (a) A (b)
*6( 4n a counter<)low heat e0changer& cold )luid enters at -;B. and lea!es at 3;B.& whereas
the hot )luid enters at '3;B. and lea!es at '-;B.( The 2#T@ is
a) ';;B. b) *8;B. c) ;B. d) *;
*7( +hat is the best<suited um )or uming hea!y )uel oil1
a) centri)ugal um b) gear um c) diahragm um d) lunger um
*8( +hich o) the )ollowing comonents in )uel limits e0it )lue gas temerature in a boiler waste
heat reco!ery system1
a) hydrogen content b) !olatile matter c) sulhur content d) ash content
*9( +hich o) the )ollowing requires the largest amount o) o0ygen?kg o) substance )or
combustion1
a) carbon b) hydrogen c) sulhur d) nitrogen
-;( A aer lant needs steam at -(3 bar and ';(3 bar in addition to electric ower( The most
suitable choice among the )ollowing will be
a) condensing turbine b) bottoming cycle
c) back ressure turbine d) e0traction cum back ressure turbine
-'( An increase in the steam ressure )rom - bar to '; bar& will result in a decrease o)
a) sensible heat b) enthaly o) steam c) saturation temerature d) seci)ic !olume
-*( .hemical used )or do:ing boiler drum to reduce dissol!ed gases is
a) hydra:ine b) chlorine c) alum d) all o) the abo!e
--( ,aturated steam when throttled to a lower ressure results in
a) wet steam b) suer heated steam c) suer critical steam d) same state o) steam
-/( Radiation losses )rom the sur)ace o) a boiler ractically
a) increase with increase in its C loading b) decrease with increase in its C loading
c) are indeendent o) its loading d) none o) the abo!e
-3( 4n oil )ired boiler& the measured ."* in )lue gas is '' C by !olume against the theoretical
."* o) '3(3C ( The ercentage e0cess air will be
a) /;(9C b) -8(7C c) */;(9C d) none o) the abo!e
-6( +hich o) the )ollowing )uel )ired steam boiler will ha!e the least e!aoration ratio1
a) coal b) bagasse c) oil d) gas
/
_______________________
$ureau o) Energy E))iciency
Paper 2 Set A Key
-7( ____ indicates the so)tening temerature o) the re)ractory
a) re)ractoriness under load (RD2) b) cold crushing strength
c) yrometric cone equi!alent (P.E) d) orosity
-8( An increase in bulk density o) a re)ractory increases its
a) !olume stability b) heat caacity c) resistance to slag enetration d) all o) the abo!e
-9( The insulation material used )or medium temerature alication is
a) calcium silicate b) olyurethane c) wood d) mica
/;( A coal )ired 5$. boiler can oerate at ___ e0cess air
a) - E / C b) *; <*3 C c) -; E /; C d) '; E '3 C
/'( The balance dra)t )urnace is one using
a) induced dra)t )an and chimney b) induced dra)t )an and )orced dra)t )an
c) )orced dra)t )an and chimney d) without induced and )orced dra)t )ans
/*( %igher e0cess air in an oil )ired )urnace would result in
a) increased )urnace temerature b) increase in ."* resence in )lue gas
c) reduced )lame temerature d) all o) the abo!e
/-( ________ is the commonly emloyed )lu0 in a cuola )urnace
a) calcium carbide b) )luorsar c) limestone d) any o) the abo!e
//( $y installing a recuerator &'C )uel reduction is ossible )or e!ery ___ reduction in )lue
gas temerature
a) 3B. b) --B. c) **B. d) ';B.
/3( The heat loss rate )rom a sur)ace is e0ressed in
a) Foules b) +?m
*
B. c) +att?sec d) k.al?m
*
?hr
/6( +hich among the )ollowing uses a working )luid )or heat reco!ery 1
a) heat ie b) recuerator c) heat wheel d) regenerator
/7( +hich o) the )ollowing is most suitable )or high temerature waste heat reco!ery 1
a) heat wheel b) heat um c) heat ie d) recuerator
/8( Among the )ollowing& cogeneration concet is not alicable to which tye o) industry1
a) sugar b) aer A ul c) re)inery d) re)ractory
/9( A de!ice used to con!ert low ressure steam to high ressure steam is called
a) heat um b) heat ie c) thermocomressor d) economi:er
3;( The unit o) thermal conducti!ity is
a) + ? m
*

o
. b) +
o
. ? m
*
c) + ? m
o
. d) +
o
. ? m
. End of Section I .
3
_______________________
$ureau o) Energy E))iciency
Paper 2 Set A Key
Set)!& 0 I% O78ECTI9E TYPE Mar6,% -$ 5 1 : -$
(i!) Answer all -$ questions
(!) Each question carries !&e mark
(!i) Please hatch the aroriate o!al in the "#R answer sheet with $lack Pen or %$
encil& as er instructions
3'( The density o) a substance relati!e to water is called
a) !iscosity b) seci)ic gra!ity c) dew oint d) our oint
3*( +hich o) the )ollowing is not a unit o) !iscosity
a) Engler b) Rankine c) ,aybolt d) Redwood
3-( The amount o) heat required to raise the temerature o) ' kg o) a substance by '
o
. is
called
a) sensible heat b) latent heat c) seci)ic heat d) net calori)ic !alue
3/( +hich among the )ollowing )uels is likely to contain ma0imum ercentage o) sulhur1
a) kerosene b) diesel oil c) 2,%, d) )urnace oil

33( +hich o) the )ollowing grades o) 4ndian coal will ha!e the highest calori)ic !alue1
a) $ b) 5 c) A d) E
36( +hich o) the )ollowing is not measured in ro0imate analysis1
a) !olatile matter b) )i0ed carbon c) sulhur d) ash
37( +hich o) the )ollowing is not measured in the ultimate analysis o) a )uel 1
a) o0ygen b) )i0ed carbon c) sulhur d) nitrogen
38( .aret loss is associated with
a) combustion o) coal b) storage o) coal c) combustion o) oil d) storage o) natural gas
39( +hich o) the )ollowing is not true with resect to imroer si:ing o) coal
a) results in oor combustion b) lower e0cess air resulting in lesser stack loss
c) increase o) unburnts in ash d) lower thermal e))iciency
6;( +hich o) the )ollowing )uel constituents releases ma0imum amount o) heat er kg during
combustion 1
a) hydrogen b) carbon c) sulhur d) nitrogen
6'( +hich is the statement that is true o) a )ire tube boiler
a) has a single steam drum b) )ire is in the tubes
c) water in the tubes d) has multile steam drums
6
_______________________
$ureau o) Energy E))iciency
Paper 2 Set A Key
6*( .oal is not burnt in susension in
a) )luidised bed boiler b) chain<grate boler
c) sreader stoker boiler d) ul!erised )uel )ired boiler
6-( +hich o) the )ollowing is considered in the calculation o) =E!aoration ratio>1
a) calori)ic !alue o) )uel b) latent heat o) steam c) )uel quantity d) all o) the abo!e
6/( +hen solutions o) di))ering concentrations are searated by a semi<ermeable membrane&
water )rom less concentrated solution asses through the membrane to dilute the liquid o)
high concentration( This is called
a) re!erse osmosis b) ion e0change c) so)tening d) osmosis
63( 5lash steam can be reco!ered )rom
a) suerheated steam b) saturated steam
c) high ressure condensate d) condensate at atmosheric ressure

66( +hich o) these is not true o) =critical oint> o) steam?water mi0ture 1
a) the temerature at critical oint is -7/('3
o
.
b) the ressure at critical oint is **'(* bar
c) saturated liquid and saturated !aour lines meet at critical oint
d) enthaly o) e!aoration is ma0imum at critical oint
67( The head loss due to )riction in a ie is
a) directly roortional to the diameter b) directly roortional to the gra!itational constant
c) in!ersely roortional to the !elocity d) directly roortional to the square o) !elocity
68( ,elect the wrong statement with resect to steam tras
a) discharges condensate as soon as it is )ormed
b) does not allow steam to escae
c) caable o) discharging air and other incondensable gases
d) does not allow condensate to escae
69( %eat trans)er in a )urnace is e))ected by
a) radiation )rom )lame b) radiation )rom )urnace walls
c) con!ection due to mo!ement o) hot gases o!er the stock d) all o) the abo!e
7;( 4n a coke )ired cuola& carbon mono0ide is roduced in the
a) reheating :one b) reducing :one
c) combustion :one d) melting :one
7'( 4n an oil )ired heat treatment )urnace which o) the )ollowing is not required to determine its
e))iciency by direct method
7
_______________________
$ureau o) Energy E))iciency
Paper 2 Set A Key
a) weight o) inut material b) o0ygen ercentage in )lue gas
c) )uel consumtion d) calori)ic !alue o) )uel
7*( +hich o) the )ollowing may not hel in energy e))icient )urnace oeration1
a) maintaining a ositi!e dra)t inside the )urnace
b) minimi:ing re)ractory losses
c) comlete combustion with ma0imum e0cess air
d) use o) ceramic )ibre in batch tye )urnace
7-( ,elect the wrong statement with resect to )urnace oerations
a) the burner )lame should not touch the stock
b) air in)iltration leads to o0idation o) billets
c) ceramic )ibre linings are used in the e0terior o) the )urnace
d) heat loss through oenings is roortional to T
/

7/( The e))ecti!eness o) a heat e0changer does not deend on
a) seci)ic heat o) hot )luid b) 4nlet temerature o) hot )luid
c) 2#T@ d) 4nlet temerature o) cold )luid
8
_______________________
$ureau o) Energy E))iciency
Paper 2 Set A Key
73( Pinch analysis uses the _____ law o) thermodynamics
a) 5irst b) ,econd c)Third d) $oth (a) A (b)
76( 4n a counter<)low heat e0changer& cold )luid enters at -;B. and lea!es at 3;B.& whereas
the hot )luid enters at '3;B. and lea!es at '-;B.( The 2#T@ is
a) ';;B. b) *8;B. c) ;B. d) *;
77( +hat is the best<suited um )or uming hea!y )uel oil1
a) centri)ugal um b) gear um c) diahragm um d) lunger um
78( +hich o) the )ollowing comonents in )uel limits e0it )lue gas temerature in a boiler waste
heat reco!ery system1
a) hydrogen content b) !olatile matter c) sulhur content d) ash content
79( +hich o) the )ollowing requires the largest amount o) o0ygen?kg o) substance )or
combustion1
a) carbon b) hydrogen c) sulhur d) nitrogen
8;( A aer lant needs steam at -(3 bar and ';(3 bar in addition to electric ower( The most
suitable choice among the )ollowing will be
a) condensing turbine b) bottoming cycle
c) back ressure turbine d) e0traction cum back ressure turbine
8'( An increase in the steam ressure )rom - bar to '; bar& will result in a decrease o)
a) sensible heat b) enthaly o) steam c) saturation temerature d) seci)ic !olume
8*( .hemical used )or do:ing boiler drum to reduce dissol!ed gases is
a) hydra:ine b) chlorine c) alum d) all o) the abo!e
8-( ,aturated steam when throttled to a lower ressure results in
a) wet steam b) suer heated steam c) suer critical steam d) same state o) steam
8/( Radiation losses )rom the sur)ace o) a boiler ractically
a) increase with increase in its C loading b) decrease with increase in its C loading
c) are indeendent o) its loading d) none o) the abo!e
83( 4n oil )ired boiler& the measured ."* in )lue gas is '' C by !olume against the theoretical
."* o) '3(3C ( The ercentage e0cess air will be
a) /;(9C b) -8(7C c) */;(9C d) none o) the abo!e
86( +hich o) the )ollowing )uel )ired steam boiler will ha!e the least e!aoration ratio1
a) coal b) bagasse c) oil d) gas
9
_______________________
$ureau o) Energy E))iciency
Paper 2 Set A Key
87( ____ indicates the so)tening temerature o) the re)ractory
a) re)ractoriness under load (RD2) b) cold crushing strength
c) yrometric cone equi!alent (P.E) d) orosity
88( An increase in bulk density o) a re)ractory increases its
a) !olume stability b) heat caacity c) resistance to slag enetration d) all o) the abo!e
89( The insulation material used )or medium temerature alication is
a) calcium silicate b) olyurethane c) wood d) mica
9;( A coal )ired 5$. boiler can oerate at ___ e0cess air
a) - E / C b) *; <*3 C c) -; E /; C d) '; E '3 C
9'( The balance dra)t )urnace is one using
a) induced dra)t )an and chimney b) induced dra)t )an and )orced dra)t )an
c) )orced dra)t )an and chimney d) without induced and )orced dra)t )ans
9*( %igher e0cess air in an oil )ired )urnace would result in
a) increased )urnace temerature b) increase in ."* resence in )lue gas
c) reduced )lame temerature d) all o) the abo!e
9-( ________ is the commonly emloyed )lu0 in a cuola )urnace
a) calcium carbide b) )luorsar c) limestone d) any o) the abo!e
9/( $y installing a recuerator &'C )uel reduction is ossible )or e!ery ___ reduction in )lue
gas temerature
a) 3B. b) --B. c) **B. d) ';B.
93( The heat loss rate )rom a sur)ace is e0ressed in
a) Foules b) +?m
*
B. c) +att?sec d) k.al?m
*
?hr
96( +hich among the )ollowing uses a working )luid )or heat reco!ery 1
a) heat ie b) recuerator c) heat wheel d) regenerator
97( +hich o) the )ollowing is most suitable )or high temerature waste heat reco!ery 1
a) heat wheel b) heat um c) heat ie d) recuerator
98( Among the )ollowing& cogeneration concet is not alicable to which tye o) industry1
a) sugar b) aer A ul c) re)inery d) re)ractory
99( A de!ice used to con!ert low ressure steam to high ressure steam is called
a) heat um b) heat ie c) thermocomressor d) economi:er
';;( The unit o) thermal conducti!ity is
b) + ? m
*

o
. b) +
o
. ? m
*
c) + ? m
o
. d) +
o
. ? m
. End of Section I .
';
_______________________
$ureau o) Energy E))iciency
Paper 2 Set A Key
Set)!& II% S2ORT DESCRIPTI9E ;UESTIONS Mar6,% < 5 - : /$
(i) Answer all E)'ht questions
(ii) Each question carries F)=e marks
S01 The ,pe)()at)!& !( (3r&ae !)+ (r!* +a" a&a+y,), ), ')=e& "e+!>#
Car"!& % <2.1 ?
2y@r!'e& % 1/.- ?
O5y'e& % $.A ?
S3+ph3r % $.< ?
Bater % $./- ?
A,h !&te&t % $.C- ?
I( at3a+ *a,, !( a)r ,3pp+)e@ t! the (3r&ae ), 1C.- 6'D6' !( (3r&ae !)+# a+3+ate
the ? !( e5e,, a)r ,3pp+)e@ t! the (3r&ae.
A&, Theoretical air required )or comlete combustion
G ((''(6 H .) I (-/(8 H (%* < "* ? 8)) I (/(-3 H ,)) ? ';;

G ((''(6 H 8*(7) I (-/(8 H ('/(3 E ;(9?8)) I (/(-3 H ;(8)) ? ';;
: 1/.C4 6' D 6' !( FO
Actual mass o) air sulied G '6(3 Jg?Jg o) 5"
Actual mass o) air sulied G (' I E0cess air) H (Theoretical air)
(' I E0cess air) G '6(3 ? '/(6-
(' I E0cess air) G '('*78
E0cess air G ;('*78
E5e,, a)r ,3pp+)e@ & ? : 12.1<
S02 I& a @ryer# 1$$ *
4
Dhr !( h!t ther*) (+3)@ ), )r3+ate@ at 21$EC. The ther*) (+3)@
heater ()re@ "y !a+# !perate, at a ra&'e !( 2$EC. E,t)*ate the !a+ reF3)re*e&t )(
the ther*a+ e(())e&y !( the heater ), C-? a&@ GC9 !( the !a+ ), /2$$ 6Ca+Dhr.
C!&,)@er ,pe)() heat & @e&,)ty !( the ther*) (+3)@ t! "e $.-- 6Ca+D6'EC & <2$
6'D*
4
re,pet)=e+y.
''
_______________________
$ureau o) Energy E))iciency
Paper 2 Set A Key
Ans Absorbed heat in thermic )luid G m H . H del T
Absorbed heat in thermic )luid G (';; H 8*;) H ;(33 H *;
Absorbed heat in thermic )luid G A$2$$$ Ka+Dhr
Thermal e))iciency o) the heater G absorbed duty ? heat duty
#ass o) coal required G absorbed duty ? (e))iciency H calori)ic !alue o) coal)
#ass o) coal required G 9;*;;; ? (;(63 H /*;;)
#ass o) coal required :44$./ 6'Dhr
S04 A heat e5ha&'er ), t! "e @e,)'&e@ t! !&@e&,e a =ap!3r at the rate !( <.-
6'D,e >h)h ), a=a)+a"+e at )t, ,at3rat)!& te*perat3re !( <$
!
C. The +ate&t heat !(
!&@e&,at)!& !( =ap!3r ), --$ 68D6'. The !!+)&' >ater at 2$
!
C a&@ a (+!> rate !(
C2 6'D,e ), 3,e@ t! re*!=e the heat. Deter*)&e the LMTD !( the heat e5ha&'er.
%eat o) condensation G heat gained by the liquid
#! 0 h)g! G #c 0 .c 0 ( Tout E Tin)
8(3 0 33; G 6* 0 /(* 0 ( Tout E *;)
Tout G -7(93
o
.
2#T@ G (8; E *;) E (8; E -7(93)
2n (6;?/*(3)
G 3;(/9
o
.
S0/ L),t ()=e e&er'y ,a=)&' *ea,3re, )& a& !)+ ()re@ reheat)&' (3r&ae
'*
_______________________
$ureau o) Energy E))iciency
Paper 2 Set A Key
A&,

S0- aG Bhy @e0,3perheat)&' ), @!&e )& Pre,,3re Re@3)&' De,3perheat)&' Stat)!&,H
"G Bhy )&@)=)@3a+ trapp)&' ), pre(erre@ !=er 'r!3p trapp)&' )& a ,tea*
@),tr)"3t)!& ,y,te* H
ANS a) A reduction in steam ressure through a ressure reducing !al!e (PRK) is an
isenthalic rocess( ,aturated steam when reduced to a lower ressure results in
suer heated steam( ,ince rocess requires only saturated steam& de<suerheating
is o)ten required& to comensate )or suerheat gained in PRK alication due to
isenthalic e0ansion(
b) The steam consumtion o) a number o) units is ne!er the same at a moment o) time
and there)ore the ressure in the !arious steam saces will also be di))erent( 4t
)ollows that the ressure at the drain outlet o) a hea!ily loaded unit will be less than
in the case o) one that is lightly loaded( Now& i) all these units are connected to a
common steam tra& the condensate )rom the hea!ily loaded and there)ore lower
ressure steam sace )inds it di))icult to reach the tra as against the higher ressure
condensate roduced by lightly or artly loaded unit( The only satis)actory
arrangement& thus would be to drain each steam sace with own tra and then
connect the outlets o) the !arious tras to the common condensate return main(
S0C L),t @!>& ()=e a@=a&ta'e, !( F7C "!)+er.
ANS ,olution (any 3 )i!e o) the )ollowing):
'(%igh e))iciency E 5$. boilers can oerate with o!erall e))iciency o) 8/C
*(Reduction in boiler si:e E high heat trans)er rate o!er a small heat trans)er area
-(5uel )le0ibility E can be oerated with !ariety o) )uels
/(Ability to burn low grade )uel
3(Ability to burn )ines
6(Pollution controlE addition o) limestone?dolomite can greatly minimise ,"* )ormation
7(2ow corrosion and erosion
'-
_______________________
$ureau o) Energy E))iciency
Paper 2 Set A Key
8(No clinker )ormation
9(2ess e0cess air
';(,imle oeration& quick startu
''(5ast resonse to load )luctuations
'*(No soot blowing
'-(Pro!ision o) automatic coal and ash handling systems
'/(Pro!ision o) automatic ignition system
'3(%igh reliability
'6(Reduced maintenance
'7(Luick resonse to changing demand
'8(%igh e))iciency o) ower generation
S01 aG Bhy ,tea* ), *!,t pre(erre@ heat)&' *e@)a )& pr!e,, )&@3,tr)e,H
"G Bhy ,at3rate@ ,tea* ), pre(erre@ !=er ,3perheate@ !r >et ,tea* (!r )&@)ret
heat)&' )& a pr!e,,H
ANS
,team is most re)erred )or )ollowing reasons
Kery high heat content
Mi!es u heat at constant temerature
Produced )rom water (chea& lenti)ul)
.lean& odorless& tasteless
4t>s heat can be used o!er and o!er
.an generate ower& then used )or heating
.an be readily distributed& easily controlled

,aturated steam has a high heat trans)er coe))icient 4t immediately releases the latent
heat on contacting the cold sur)ace( ,o heat trans)er is )aster and at uni)orm
temerature( ,uerheated steam has a low heat trans)er coe))icient and )irst it has to
gi!e u it suerheat which haens slowly and then once it reaches the saturation state
it gi!es u the latent heat( ,o it takes more time to heat with suerheated steam( %ence
saturated steam is re)erred(
S0<
F!r a - t!&&eDh!3r apa)ty (3r&ae !)+ ()re@ "!)+er# e,t)*ate the r),e )&
te*perat3re !( >ater )& a& e!&!*)Ier# >h)h "r)&', @!>& the (+3e 'a,
te*perat3re (r!* 41$
!
C t! 1<$ JC. A)r t! (3e+ rat)! a&@ e=ap!rat)!& rat)! !( the
"!)+er are 2$ a&@ 1$ re,pet)=e+y. A,,3*e !&@e&,ate re!=ery ), &)+. Spe)()
heat !( (+3e 'a, ), $.24 6Ca+D6'
O
C
'/
_______________________
$ureau o) Energy E))iciency
Paper 2 Set A Key
5or ' kg o) )uel steam generated is G '; kg
5or ' kg o) )uel makeu water is G '; kg
5or ' kg o) )uel required combustion air is G *; kg
5or ' kg o) )uel )lue gas generated is G *; I'G *' kg
4n economi:er heat gi!en by )lue gas G heat recei!ed by makeu water
*' 0 ;(*- 0 (-';<'8;) G '; 0 ' 0 T
T G C2.< JC
------- End of Section - II ---------
'3
_______________________
$ureau o) Energy E))iciency
Paper 2 Set A Key
Set)!& III% LONG DESCRIPTI9E ;UESTIONS Mar6,% C 5 1$ : C$
(i) Answer all S)5 questions
(ii) Each question carries Te& marks
L01 A& !)+ ()re@ "!)+er ), 'e&erat)&' 4$ TDhr Stea* a&@ !perate, (!r <$$$ hr,Dyear. The
TDS )& "!)+er (ee@ >ater >a, re@3e@ (r!* -$$ pp* t! 2$$ pp*. The *a5)*3*
per*),,)"+e +)*)t !( TDS )& the "!)+er ), 4$$$ pp* a&@ *a6e 3p >ater ), 1$?.
Te*perat3re !( the "+!> @!>& >ater ), 11$EC a&@ "!)+er (ee@ >ater te*perat3re ),
/$EC. GC9 !( (3e+ ), 1$$$$ 6Ca+D6' a&@ e(())e&y !( the "!)+er ), <$?.
Ca+3+ate the ,a=)&', )& (3e+ !)+ per a&&3* @3e t! re@3t)!& )& the "+!> @!>&
ANS $low down C G 5eed water T@, H C make u water H ';; ? (ma0imum ermissible
T@, in boiler water E 5eed water T@,)

4nitial blow down G 3;; H '; ? (-;;; E 3;;)
4nitial blow down G *(; C

4mro!ed blow down G *;; H '; ? (-;;; E *;;)
4mro!ed blow down G ;(7' C

Reduction in blow down G *(; E ;(7'
Reduction in blow down G '(*9 C
Reduction in blow down G '(*9 H -; H ';;; ? ';;
Reduction in blow down G -87 kg?hr

%eat sa!ings G -87 H ' H ('7; E /;)
%eat sa!ings G 3;-'; kcal?hr
5uel "il sa!ing G 3;-'; ? (';;;; H ;(8) G 6(*8 kg?hr
G 6(*8 H 8;;; hr G -$.2/ MT D a&&3*

L02 aG Dra> the ,he*at), !( a heat p3*p ,y,te* a&@ ,tate t>! e5a*p+e, !( heat
p3*p app+)at)!&,.
"G A& !)+ ()re@ "!)+er ha, the (!++!>)&' !perat)&' para*eter,
Stea* 'e&erat)!& % - TDhr
Stea* pre,,3re % < 6'D*
2
'6
_______________________
$ureau o) Energy E))iciency
Paper 2 Set A Key
Fee@ >ater te*perat3re % -$ EC
Stea* e&tha+py % CC$ 6Ca+D6'
Stea* Sat3rat)!& te*perat3re % 11$ EC
GC9 !( (3e+ !)+ % A--$ 6Ca+D6'
C!&,3*pt)!& !( (3e+ !)+ % 4$$ 6'Dhr
Ca+3+ate the "!)+er e(())e&y )( the @ry&e,, (rat)!& ), $.<.
ANS a) Re)er $ook -& Page No( **9<*-;
b) ,team generated G 3 T?hr
@ry steam G / T?hr
+et steam G ' T?hr
Total heat o) the steam G /;;; H (66;<3;) I ';;;H'H('7; E 3;)
Total heat o) the steam G *(36 H ';
6
Jcal?hr
$oiler E))iciency G %eat o) steam ? (mass o) )uel H calori)ic !alue)
$oiler E))iciency G *(36 H ';6 ? (-;; H 933;) H ';;
A&,>er%
7!)+er E(())e&y : <A.4 ?


'7
_______________________
$ureau o) Energy E))iciency
Paper 2 Set A Key
L04 I& a r3@e @),t)++at)!& 3&)t !( a re()&ery# -$ Metr)T!&&eDhr !( r3@e ), heate@ 3,)&'
,at3rate@ ,tea* )& a heat e5ha&'er (r!* 4-EC t! <-EC. P+a&t ), !perat)&' (!r <$$$
hr,Da&&3*. C!&,)@er ,pe)() heat !( the r3@e a, $.C41 6Ca+D6'EC. The p+a&t ha,
t>! ,tea* hea@er, !perat)&' at 4 "ar a&@ < "ar re,pet)=e+y# pa,,)&' &ear"y the
heat e5ha&'er. C!,t !( ,tea* ), ,a*e (!r "!th 4 "ar a&@ < "ar K R,./.-$D6'
A, a& E&er'y Ma&a'er# >h)h !( the (!++!>)&' !pt)!&, >)++ y!3 re!**e&@ t! the
3&)t "a,e@ !& the a&&3a+ !,t !( ,tea*H
aG Ut)+),)&' 4 "ar ,tea*
"G Ut)+),)&' < "ar ,tea*
G)=e&% Data (r!* ,tea* ta"+e%
Stea*
Pre,,3re#
"ar
E&tha+py 6Ca+D6'
Bater E=ap!rat)!& Stea*
4.$ 144 -11 C-$
<.$ 111 /<A CC$
ANS %eat gain in crude G m H . H del T
%eat gain in crude G 3; H ';;; H ;(6-' H (83 E -3)
%eat gain in crude G '3773;; k.al?hr
%eat gain in crude G heat loss in steam
%eat loss in steam G mass o) the steam H latent heat o) steam
Opt)!& A%
- bar ressure steam ha!ing 3'7 Jcal?kg o) latent heat
#ass o) the steam G '3773;; ? 3'7
#ass o) the steam G -;3' kg ? hr
.ost o) steam e0enditure G -;3' H 8;;; H /(3
.ost o) steam e0enditure G ';(98 .r
Opt)!& 7%
8 bar ressure steam ha!ing /89 Jcal?kg o) latent heat
#ass o) the steam G '3773;; ? /89
#ass o) the steam G -**3 kg ? hr
.ost o) steam e0enditure G -**6 H 8;;; H /(3
.ost o) steam e0enditure G ''(6' .r
A&,>er:
"tion A is recommended as it is )ound to be economical (,team N - bar ressure) since
the e0enditure er annum is less when comared to "tion $(
'8
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$ureau o) Energy E))iciency
Paper 2 Set A Key
L0/ Ma6e a& )++3,trat)=e ,6eth !( the (!++!>)&',
aG ,)*p+e "a6 pre,,3re t3r")&e
"G @!3"+e e5trat)!& "a6 pre,,3re t3r")&e
G @!3"+e e5trat)!& !&@e&,)&' t3r")&e
@G 'a, t3r")&e !*")&e@ y+e
ANS
a) b) (c)
d)

L0- I& a !3&ter (+!> heat e5ha&'er# >ater ), "e)&' h)++e@ "y ,!@)3* h+!r)@e "r)&e.
The rate !( (+!> !( the "r)&e ), 2.1 6'D, a&@ that !( the >ater ), 1.-< 6'D,. E,t)*ate
'9
_______________________
$ureau o) Energy E))iciency
Paper 2 Set A Key
the te*perat3re t! >h)h the >ater ), !!+e@ )( the "r)&e e&ter, at < EC a&@ +ea=e,
at 1$ EC# a&@ )( the >ater e&ter, the e5ha&'er at 4< EC. Ca+3+ate the area !( the
heat e5ha&'er ,3r(ae )( the !=era++ heat tra&,(er !0e(())e&t ), 1$$ 8D*
2
,EC.
C!&,)@er the ,pe)() heat !( "r)&e a&@ >ater ), 4.4< & /.1< 68D6'EC re,pet)=e+y.
ANS %eat gain by brine G heat lost by water
*(7 H -(-8 H (';<(<8)) G '(38 H /('8 H (-8 E T)
T G '-(* B.
i) +ater lea!es the e0changer at '-(*B.

ii) 2#T@ o) counter )low attern

=
) 8 ( 2 . 13 (
10 38 (
ln
) 8 ( 2 . 13 ( ) 10 38 (
LMTD
T
32 . 1 ln
8 . 6
=
LMTD
T
G */(/ B.

L G mH.H @el T G D H A H 2#T@
*(7 H -(-8 H ('; E (<8)) H ';;; G ';; H A H */(/
A G 67(- m*
Area o) the heat e0changer sur)ace is C1.4 *2
L0C Br)te ,h!rt &!te, !& a&y t>! !( the (!++!>)&'
aG 'e&era+ reF3)re*e&t, !( re(rat!ry *ater)a+ (!r (3r&ae app+)at)!&
"G a3,e, !( "!)+er t3"e +ea6a'e,
G ther*!!*pre,,!r
@G heat p)pe
*;
_______________________
$ureau o) Energy E))iciency
Paper 2 Set A Key
ANS aG ReF3)re*e&t, !( re(rat!ry *ater)a+
a) Ability to withstand high temperatures.
b) Ability to withstand sudden changes o temperatures.
c) Ability to withstand action o molten metal slag! glass! hot gases! etc.
d) Ability to withstand load at ser"ice conditions.
e) Ability to withstand load and abrasi"e orces.
) #ow coeicient o thermal e$pansion.
g) %hould be able to conser"e heat.
h) %hould not contaminate the material with which it comes into contact.
b) Tube )ailures can be attributed to design& manu)acturing& oerational& maintenance and
ageing related asects( The tube )ailures mechanisms can be classi)ied as #echanical&
chemical& metallurgical A in adequate quality comliance(
Meha&)a+ a3,e,
#echanical damage o) tubes takes lace due to )ly ash erosion& steam imingement )rom
soot blowers& )alling clinker and )uel articles( The #echanical damage increases the
stress le!el leading to tube )ailure(
Che*)a+ a3,e,
+ater side and )ire side corrosion )ailure o) tubes occurs due to henomenon like caustic
gouging& hydrogen embrittlement& itting& and stress corrosion cracking while )ire side
corrosion is o)ten due to high as well as low temerature e))ects
Meta++3r')a+ a3,e,
4n high tem comonents like suerheaters& reheaters cree damage occurs due to
o!erheating wherein the tube material loses its strength and )ailure occurs by stress
ruture( +eld Ooint )ailures by cracking and )atigue )ailures by !ibration& thermal and
corrosion henomenon are other reasons )or metallurgical related tube )ailures(
;3a+)ty a,,3ra&e 'ap,
Tube )ailures are also known to occur due to inadequate quality assurance rocedures
during design?manu)acturing o) boiler tubes( @ue care during material rocurement&
adotion o) healthy )abrication ractices& good oeration and maintenance ractices in
tube manu)acturing would hel to minimi:e tube leakages and achie!e high a!ailability(

G Ther*!!*pre,,!r
*'
_______________________
$ureau o) Energy E))iciency

Paper 2 Set A Key
4n many o) the steam utili:ation equiment where
condensate comes out at high ressure& a maOor
ortion o) it )lashes into low ressure steam which
goes wasted( Dsing a thermocomressor it becomes
)easible to comress this low ressure steam by high
ressure steam and reuse it as a medium ressure
steam in the rocess( The maOor energy in steam is in
its latent heat !alue and thus thermocomressing
would gi!e a large imro!ement in waste heat
reco!ery(
Thermocomressors are designed to accurately mi0
lower<ressure steam with higher<ressure steam(
The higher<ressure moti!e steam entrains the lower
ressure steam and increases its ressure( The
moti!e steam is introduced through the no::le o) the
thermocomressor( As the no::le oens& the high
!elocity moti!e steam draws the lower<ressure
steam into the thermocomressor body( An e0change
o) momentum occurs as the steam )lows are mi0ed
and the mi0ed )low is accelerated to high !elocity with
a uni)orm ro)ile in the mi0ing chamber o) the
thermocomressor( As the mi0ed )low enters the
di))user section& the di))user )low area gradually
increases to allow the !elocity o) the mi0ed )low to
be reduced( As the !elocity is reduced& the steam ressure increases( At the end o) the
di))user& the discharge steam ressure is higher than the lower<ressure suction )low
entering the thermocomressor( A )igure o) thermocomressor is shown in 5igure -(7( A
tyical alication is in e!aorators where the boiling steam is recomressed and used as
heating steam(
d) 2eat P)pe
A heat ie can trans)er u to ';; times more thermal energy than coer& the best
known conductor( 4n other words& heat ie is a thermal energy absorbing and trans)erring
system and ha!e no mo!ing arts and hence require minimum maintenance(
**
_______________________
$ureau o) Energy E))iciency
Paper 2 Set A Key
The %eat Pie comrises o) three elements E a sealed container& a caillary wick structure
and a working )luid( The caillary wick structure is integrally )abricated into the interior
sur)ace o) the container tube and sealed under !acuum( Thermal energy alied to the
e0ternal sur)ace o) the heat ie is in equilibrium with its own !aour as the container tube
is sealed under !acuum( Thermal energy alied to the e0ternal sur)ace o) the heat ie
causes the working )luid near the sur)ace to e!aorate instantaneously( Kaour thus
)ormed absorbs the latent heat o) !aourisation and this art o) the heat ie becomes an
e!aorator region( The !aour then tra!els to the other end the ie where the thermal
energy is remo!ed causing the !aour to condense into liquid again& thereby gi!ing u the
latent heat o) the condensation( This art o) the heat ie works as the condenser region(
The condensed liquid then )lows back to the e!aorated region( A )igure o) %eat ie is
shown in 5igure


-------- End of Section - III ---------
*-
_______________________
$ureau o) Energy E))iciency