Paper 2 - Set A Key

14
th
NATIONAL CERTIFICATION EXAMINATION
FOR
ENERGY MANAGERS & ENERGY AUITORS ! A"#"$t% 2&1'
PAPER ! 2( E)er#y E**+,+e),y +) Ther-a. Ut+.+t+e$
ate( 24/0/2&1' T+-+)#$(14(&& -11(&& 2r$ "rat+3)(' 2r$
Ma4/Mar5$(16&
Se,t+3) ! I( O78ECTI9E TYPE Mar5$(
6& 4 1 : 6&
(i) Answer all 6& questions
(ii) Each question carries 3)e mark
(iii) Please hatch the appropriate oval in the OMR answer sheet with Black Pen or HB
pencil
1. In coal fired comustion! the flame len"th is influenced #
a) moisture ) ash content c) volatile matter d) fi$ed
caron
%. &ith increase in the percenta"e of e$cess air for comustion of coal! percenta"e of
'(
%
in flue "as
a) increases ) decreases c) remains same d) none of the
aove
). 1** k" of a fuel contains )+ sulphur. ,or complete comustion of sulphur in the fuel
it will require ---------k" of o$#"en
a) ) ) . c) )* d) 1*)
/. &hich propert# indicates the lowest temperature at which fuel oil is readil# pumpale0
a) flash point ) pour point c) specific heat d) specific
volume
1. &hich of the followin" contriutes to splutterin" of flame at urner tip durin"
comustion of fuel oil 0
a) ash content ) water content c) sulphur content d) humidit# of
air
.. In an oil fired steam oiler the air to fuel ratio is 1121 3 evaporation ratio is 1/21. 4he
flue "as to fuel ratio will e
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Bureau of Ener"# Efficienc#
1
Paper 2 - Set A Key
a) %521 ) 1.21 c) 1/21 d) 1121
6. &hich amon" the followin" fuels! on comustion !has hi"her tendenc# towards acid
corrosion in the flue "as path0
a) a) 78H8 ) furnace oil c) 9iesel
d) kerosene
:. 4he alanced draft furnace is one that is operated with
a) a) positive pressure ) induced and forced
draft fan
b) c) ne"ative pressure d) ;atural draft
5. 4he factor that influences atomisation of fuel oil is
a) viscosit# ) densit# c) flash point d) pour point
1*. &hich of the followin" is not measured in ultimate anal#sis 0
a) caron ) sulphur c) h#dro"en d)
moisture
11. In flue "as! the o$#"en measured is /+ # volume. 4he percenta"e e$cess air will e
a) a) %).1+ ) /*+ c) %1+
d) ).+
1%. A oiler "enerates 1 4PH of steam at an efficienc# of 6: +. 4he enthalp# added to
steam in the oiler is 1:* kcal<k". 4he fuel consumption with a ='> of /%** kcal<k"
is
a) ::1 k"<hr ) 5:1 k"<hr c) 1*): k"<hr d) 1%**
k"<hr
1). Automatic lowdown controls for oilers work # sensin"
a) dissolved "ases ) dissolved solids c) pH d) conductivit#
and pH
1/. 9issolved '(
%
in oiler feed water when left untreated would result in occurrence of
-----in oiler tues
a) creep ) water side corrosion c) scale d) water
hammer
11. ?ecommended oiler feed water pH value at %1
o
' is @@@@@@@@@
a) :.* @ 5.* ) 1.% @ ..% c) 5.:@1*.% d) 1*@1*.1
1.. &hich of the followin" is not applicale in the preservation of oiler # dr# method 0
a) un@slacked lime ) activated alumina
c) anh#drous calcium cloride d) h#draAine
2
Paper 2 - Set A Key
16. &hich one of the followin" is true of a water softenin" process0
a) It reduces hardness ut not 498 ) It reduces oth hardness and 498
c) It reduces 498 ut not hardness d) ;one of the aove
1:. 8oot deposit in oiler tues is predominantl# due to
a) poor water treatment ) low steam pressure
c) incomplete comustion d) hi"h e$cess air
15. &hich of the followin" will e the most suitale heatin" medium for heat transfer in
indirect heatin"0
a) dr# saturated steam ) superheated steam c) wet steam d) hot
water
%*. 4en meter lift of condensate in a distriution pipe will result in a ack pressure of
a) *.1 ar ) 1 ar c) 1* ar d)
1.1 ar
%1. 4he difference in temperature etween steam and condensate is the principle of
operation of
a) thermod#namic trap ) thermostatic trap c) orifice t#pe trap d) float trap
%%. &ater flows at a rate of )* m
)
<hr. at 11
o
' in a 11* mm ore pipe horiAontall#. &hat is
the velocit# of water flow in the pipe0
a) *./6 m<s ) *.5/ m<s c) 1.:: m<s d) ).6 m<s
%). 4o drain condensate from tracer steam lines ! the most common trap used
is---------
a) thermod#namic ) imetallic c) inverted ucket d) float trap
%/. 4he velocit# of steam in steam pipe is directl# proportional to
a) numer of ends in pipe ) specific volume of steam
c) len"th of pipe d) fifth power of pipe diameter
%1. 'ondensate! at ) ar pressure 3 1.*B'! when e$posed to atmosphere will
a) full# convert to flash steam ) partl# convert to flash steam
c) remain as condensate d) convert to superheated steam
%.. 8team at / ar has sensile heat of 1// kcal<k" and latent heat of 11* kcal<k". If the
steam is 5*+ dr# than the total enthalp# of steam in kcal<k" is
a) 1:: ) .1/ c) .*) d) /15
%6. ,or transportin" steam to a lon" distance! the most suitale amon" the followin" will
e
a) sli"htl# superheated steam ) dr# saturated steam
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Bureau of Ener"# Efficienc#
3
Paper 2 - Set A Key
c) mildl# wet steam d) hi"h pressure steam
%:. Heat transfer in a reheatin" furnace is achieved #
a) conduction ) convection c) radiation d) all of the aove
%5. &hich of the followin" is not a propert# of ceramic fire 0
a) low thermal conductivit# ) li"ht wei"ht
c) hi"h heat capacit# d) thermal shock resistant
)*. 4he unit of overall heat transfer coefficient is
a) kcal<m@hr@B' ) kcal< mC@hr@B' c) kcal<mC@B' d)
kcal< m@B'
)1. &hich propert# of ceramic coatin" influences ener"# savin"s in furnaces0
a) emissivit# ) coatin" thickness
c) conductivit# d) convective heat transfer coefficient
)%. In a ',B' oiler the capture and rec#clin" of ed materials is accomplished #
a) elecrostatic precipitator ) a" filter c) c#clone d) scruer
)). &hat is the most effective wa# to avoid amient air infiltration into a continuous
furnace0
a) close all openin"s ) increase the chimne# hei"ht
c) operate at aout 5*+ capacit# d) maintain sli"htl# positive pressure inside the
furnace
)/. 4he stora"e heat losses in a atch t#pe furnace can e est reduced # use of
a) hot face insulatin" ricks ) hot face ceramic fire
c) cold face insulatin" ricks d) cold face ceramic fire
)1. 4u#eres is a terminolo"# associated with
a) for"in" furnace ) cupola c) open hearth furnace d) heat treatment
furnace
).. &hich of the followin" is a s#nthetic refractor#0
a) D"( ) Al
%
(
)
c) 8i' d) 8i(
%
)6. Alumina is a ------------------ t#pe of refractor#
a) asic ) acidic ,; neutral d) none of the aove
):. An increase in ulk densit# of a refractor# increases its
a) volume stailit# ) heat capacit#
c) resistance to sla" penetration d) all of the aove
4
Paper 2 - Set A Key
)5. &hich of these is used in a fluidised ed oiler to control sulphur dio$ide emissions0
a) charcoal ) limestone c) sand d) silica
/*. In ,B' oiler the comustion is carried out at a temperature
a) closer to steam temperature ) at adiaatic comustion temperature
c) at and aove ash fusion temperature d) elow ash fusion temperature of fuel used
/1. 7ow comustion temperature minimises--- in ,B' oilers
a; NO4 ) 8($ c) '( d) 8uspended particulate matter
/%. A chemical plant needs steam at ) ar and 1* ar in addition to electric power. 4he
most suitale co@"eneration choice amon" the followin" will e
a) e$traction cum condensin" ) condensin" turine
c) ack pressure turine d) e$traction cum ack pressure turine
/). Power is to e "enerated from a cement kiln e$haust "as. 4he applicale t#pe of
co"eneration is called
a) toppin" c#cle ) 'arnot c#cle c) ottomin" c#cle d) Bra#ton
c#cle
//. &hich of the followin" works on a refri"eration c#cle0
a) heat pipe ) heat wheel c) heat pump d) thermo compressor
/1. &hich of these devices can e used for recoverin" waste heat from the te$tile drier
e$haust0
a) heat wheel ) recuperator c) economiAer d)
re"enerator
/.. &ick in heat pipe is provided to facilitate
a) forward movement of hot vapors ) forward movement of hot liquid
c) return of condensed liquid d) return of hot vapors
/6. &hich of the followin" requires electrical ener"# for equipment operation0
a) thermo compressor ) heat pump c) heat pipe d)
economiAer
/:. 4he e$haust from which of the followin" is not suitale for waste heat oiler
application0
a) "as turine ) hot air dr#er c) diesel en"ine d) furnace
/5. Pinch anal#sis of process streams depicts the plot of
a) temperature vs entrop# ) temperature vs area
c) temperature vs specific heat d) temperature vs enthalp#
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Bureau of Ener"# Efficienc#
5
Paper 2 - Set A Key
1*. 'orrection factor for 7D49 calculation is applicale for
a) parallel flow ) counter current flow c) cross flow d) oth (a)
3 ()
. End of Section I .
6
Paper 2 - Set A Key
Se,t+3) - II( S2ORT ESCRIPTI9E <UESTIONS Mar5$( 0 4 6 :
4&
(i) Answer all E+#ht questions
(ii) Each question carries F+=e marks
S-1
The *3..3>+)# are the para-eter$ 3?ta+)e@ *r3- a $tea- a"@+t 3* a ,y.+)@r+,a.
@ryer "$e@ *3r @ry+)# ,.3th/
C.3th Thr3"#hp"t : 2& -A-+)"te
C.3th e)$+ty : B/0 -A5#


Mea$"re@ C3)@e)$ate Rate : 1'6 5#Ah3"r
Ca.,".ate the $pe,+*+, $tea- ,3)$"-pt+3) per 5# 3* ,.3th/
'loth throu"hput per hour E %* $ .* E 1%** m<hr
&ei"ht of cloth E 1%** < 5.:
E 1%%./1 k"<hr
8team consumption E condensate collected
8pecific steam consumption E 1)1<1%%./1 E1.1 k" of steam per k" of cloth
S-2
I) a ,r"@e @+$t+..at+3) ")+t 3* a re*+)ery% *"r)a,e +$ 3perate@ t3 heat '&& 5+.3
L+tre$Ahr 3* ,r"@e 3+. at a) +).et te-perat"re 3* 266CC ?y *+r+)# 2/6 5+.3.+tre$Ahr
3* *"r)a,e 3+. ha=+)# GC9 3* B00& 5,a.A5#/ I* the e**+,+e),y 3* the *"r)a,e +$
02D %,a.,".ate the 3"t.et te-perat"re 3* the ,r"@e 3+. *r3- the *"r)a,e/
C3)$+@er the *3..3>+)# @ata(
Spe,+*+, heat 3* Cr"@e O+. : &/E6 5,a.A5#CC
Spe,+*+, #ra=+ty 3* Cr"@e O+. : &/0E
Spe,+*+, #ra=+ty 3* *"r)a,e O+. : &/B0
8olution2
,urnace oil consumption E %.1 F *.5: E %./1 4PH
Heat input to the furnace E %./1 $ 1*** $ 5::* E %/.% $ 1*
.
Gcal<hr
Heat asored # the crude E %/.% $ 1*
.
$ *.:% E 15.:1$ 1*
.
Gcal<hr
H E m I 'p I 9el 4
15.:1 I 1*
.
E )** I *.:. I 1*** I *..1 I 4
4 E 11: B'
4 out E %11 J 11: E )6) B'
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Bureau of Ener"# Efficienc#
7
Paper 2 - Set A Key
4emperature of crude at furnace outlet is )6) B'
S-'
I) a pr3,e$$ p.a)t% 2& TP2 3* $tea- a*ter pre$$"re re@",t+3) >+th pre$$"re
re@",+)# =a.=e t3 2& 5#A,-
2
#et$ $"perheate@/ The te-perat"re 3* $tea- +$
20&
3
C/ The -a)a#e-e)t >a)t$ t3 +)$ta.. a @e-$"perheater t3 ,3)=ert
$"perheate@ $tea- +)t3 $at"rate@ $tea- at 2& 5#A,-
2
*3r pr3,e$$ "$e% a)@
+t$ $at"rat+3) te-perat"re +$ 21&
3
C/
Ca.,".ate F"a)t+ty 3* >ater at '&
3
C t3 ?e +)Ge,te@ +) @e-$"perheater t3 #et the
@e$+re@ $at"rate@ $tea- "$+)# the *3..3>+)# @ata/
Spe,+*+, heat 3* $"perheate@ $tea- : &/46 5,a.AK#
3
C
Late)t heat 3* $tea- at 2&5#A,-
2
: 46& 5,a.A5#
Answer
Quantity of heat available above saturation = 20,000 x 045 x (2!0"210)
= 6,30,000 #$al
Quantity of %ater re&uire' in 'e"su(erheater = Q x)1x (210"30) * 450+= 630000
= 1000 ,-.hr

S-4 A 6 TP2 ,apa,+ty ?3+.er +$ #e)erat+)# $at"rate@ $tea- at 0 5#A ,-
2
# /The
*3..3>+)# 3perat+)# para-eter$ >a$ -ea$"re@ @"r+)# the $"r=ey/
F"r)a,e 3+. ,3)$"-pt+3) - 2&& 5#Ahr/
GC9 3* *"r)a,e 3+. - 1&%6&& 5,a.A5#
<ty 3* $tea- #e)erat+3) - '&&& 5#Ahr
Fee@ >ater te-perat"re - E&
3
C
E)tha.py 3* @ry $at"rate@ $tea- - EE& 5,a.A5#
ry)e$$ *ra,t+3) - &/B
Sat"rat+3) te-perat"re 3* $tea- - 11&
3
C
Ca.,".ate the ?3+.er e**+,+e),y ?y @+re,t -eth3@/

/oiler 0ffi1ien1y = 2700 #- x (660"60) #1al.#- * 300 x (170"60) x 100
200 #- x 10500 #1al.#-
= 7!72
S-6
I) a phar-a +)@"$try% a ,he-+,a. pr3,e$$ reF"+re$ 6&&& 5#Ahr 3* @ry
$at"rate@ $tea- at 1 5#A,-
2
H#;/ Spe,+*+, =3."-e 3* $tea- at 1 5#A,-
2
# +$
&/24 -
'
A5# / eter-+)e the p+pe @+a-eter $+Ie *3r a $tea- *.3> =e.3,+ty 3* 26
-A$/

3he velo1ity of stea4 = 25 4.s
5(e1ifi1 volu4e at 7 #-.14
2
- = 024 4
3
.#-
6ass flo% rate of stea4 = 5000 #-.hr
!
Paper 2 - Set A Key
= 5000.3600 = 13!7 #-.se1
8olu4etri1 flo% of stea4 = 13!7 x 024 =0333 4
3
.se1
3herefore, usin- for4ula9
S-E +$t+)#"+$h ?et>ee) p.ate heat e4,ha)#er a)@ $he.. a)@ t"?e heat
e4,ha)#er J
Ans
She.. a)@ T"?e heat E4,ha)#er$
8hell@and@tue heat e$chan"ers consist of a undle of parallel tues that provide the heat@transfer
surface separatin" the two fluid streams. 4he tue@side fluid passes a$iall# throu"h the inside of
the tuesK the shell@side fluid passes over the outside of the tues. Baffles e$ternal and
perpendicular to the tues direct the flow across the tues and provide tue support.
4ue sheets seal the ends of the tues! ensurin" separation of the two streams. 4he process fluid
is usuall# placed inside the tues for ease of cleanin" or to take advanta"e of the hi"her pressure
capailit# inside the tues. 4he thermal performance of such an e$chan"er usuall# surpasses a coil
t#pe ut is less than a plate t#pe. Pressure capailit# of shell@and@tue e$chan"ers is "enerall#
hi"her than a plate t#pe ut lower than a coil t#pe.
P.ate 2eat E4,ha)#er$
Plate heat e$chan"ers consist of a stack of parallel thin plates that lie etween heav# end plates.
Each fluid stream passes alternatel# etween adLoinin" plates in the stack! e$chan"in" heat
throu"h the plates. 4he plates are corru"ated for stren"th and to enhance heat transfer # directin"
the flow and increasin" turulence. 4hese e$chan"ers have hi"h heat@transfer coefficients and
area! the pressure drop is also t#picall# low! and the# often provide ver# hi"h effectiveness.
However! the# have relativel# low pressure capailit#.
4he i""est advanta"e of the plate and frame heat e$chan"er! and a situation where it is most
often used! is when the heat transfer application calls for the cold side fluid to e$it the e$chan"er at
a temperature si"nificantl# hi"her than the hot side fluid e$it temperature i.e. Mtemperature
crossN. 4his would require several shell and tue e$chan"ers in series due to the lack of purel#
counter@current flow.
4he overall heat transfer coefficient of plate heat e$chan"ers under favorale circumstances can
e as hi"h as :!*** &<m
%
O'. &ith traditional shell and tue heat e$chan"ers! the P@value will e
elow %!1** &<m
%
O'.
S-1
G+=e rea$3)$ *3r the *3..3>+)#
a) E4p.a+) >hy )at"ra. #a$ reF"+re$ .e$$ a-3")t 3* e4,e$$ a+r ,3-pare@ t3
$3.+@A.+F"+@ *"e.$
b) Khy $tea- +$ t3 ?e "$e@ at the .3>e$t pra,t+,a?.e pre$$"re *3r +)@+re,t
pr3,e$$ heat+)# J
Ans
a; Nat"ra. #a$ reF"+re$ .e$$ a-3")t 3* e4,e$$ a+r ,3-pare@ t3 $3.+@A.+F"+@ *"e.$
;atural "as is in the "aseous form and li"hter than air! it mi$es with air readil# (intimate mi$in" of
air (o$#"en) and fuel takes place) and aids to complete comustion with less amount of e$cess air.
It does not produce smoke or soot. It has no sulphur content. It is li"hter than air and disperses into
air easil# in case of leak. ;atural "as is also free of ash.
8olid or liquid fuels must e chan"ed to a "aseous form efore the# will urn. Hence it requires
more e$cess air compared to natural "as for complete comustion. 8olid fuels need to e
pulveriAed properl# to "et uniform siAes and liquid fuels need to e preheated and atomiAed
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Bureau of Ener"# Efficienc#
7
Paper 2 - Set A Key
properl# for intimate mi$in" with air to ensure complete comustion. Hence more e$cess air is
provided for solid and liquid fuels.
?; Stea- +$ t3 ?e "$e@ at the .3>e$t pra,t+,a?.e pre$$"re *3r +)@+re,t pr3,e$$ heat+)#
A stud# of the steam tales would indicate that the latent heat in steam reduces as the steam
pressure increases. It is onl# the latent heat of steam! which takes part in the heatin" process
when applied to an indirect heatin" s#stem. 4hus! it is important that its value e kept as hi"h as
possile. 4his can onl# e achieved if we "o in for lower steam pressures. As a "uide! the steam
should alwa#s e "enerated and distriuted at the hi"hest possile pressure! ut utiliAed at as low
a pressure as possile since it then has hi"her latent heat.
However! it ma# also e seen from the steam tales that the lower the steam pressure! the lower
will e its temperature. 8ince temperature is the drivin" force for the transfer of heat at lower steam
pressures! the rate of heat transfer will e slower and the processin" time "reater. In equipment
where fi$ed losses are hi"h (e.". i" dr#in" c#linders)! there ma# even e an increase in steam
consumption at lower pressures due to increased processin" time. 4here are! however! several
equipment in certain industries where one can profital# "o in for lower pressures and realiAe
econom# in steam consumption without materiall# affectin" production time.
4herefore! there is a limit to the reduction of steam pressure. 9ependin" on the equipment desi"n!
the lowest possile steam pressure with which the equipment can work should e selected without
sacrificin" either on production time or on steam consumption.
S-0 L+$t @3>) *+=e -aG3r a@=a)ta#e$ 3* >a$te heat re,3=ery +) r3..+)# -+..
*"r)a,e
1 ,uel econom#
2 Improved combustion/less excess air/reduction in stack losses
3 Increased output
4 Reduction in scale losses
5 Uniform temperature across the material
6 Reduced pollution
7 Less auxiliary energy consumption
! Reduction in equipment sizes
------- End of Section - II ---------
Se,t+3) - III( LONG ESCRIPTI9E <UESTIONS Mar5$( E 4 1& : E&
(i) Answer all S+4 questions
(ii) Each question carries Te) marks
L-1
A) 3+. *+re@ reheat+)# *"r)a,e ha$ a) 3perat+)# te-perat"re 3* ar3")@ 1&&&
3
C/
A=era#e *"r)a,e 3+. ,3)$"-pt+3) +$ 44& .+tre$Ah3"r/ The *."e #a$ e4+t
te-perat"re a*ter the a+r preheater +$ '&&
3
C/ C3-?"$t+3) a+r +$ preheate@ *r3-
a-?+e)t te-perat"re 3* '6
3
C t3 2&&
3
C thr3"#h the a+r preheater/ The 3ther @ata
are a$ #+=e) ?e.3>/
Spe,+*+, #ra=+ty 3* 3+. : &/B2
Ca.3r+*+, =a."e 3* 3+. : 1&%2&& 5,a.A5#
A=era#e O
2
per,e)ta#e +) *."e #a$ : 14D
The3ret+,a. a+r reF"+re@ : 14 5# 3* a+r per 5# 3* 3+.
10
Paper 2 - Set A Key
Spe,+*+, heat 3* a+r : &/24 5,a.A5#
3
C
Spe,+*+, heat 3* *."e #a$ : &/2' 5,a.A5#
3
C
F+)@ 3"t the $e)$+?.e heat ,arr+e@ a>ay ?y the e4ha"$t #a$e$ a)@ heat
re,3=ere@ ?y the ,3-?"$t+3) a+r +) 5,a.Ahr a$ a per,e)ta#e 3* the e)er#y +)p"t/
Ans
Ener"# input E //* litres<hr
E //* $ *.5% k"<hr
E /*/.:* k"<hr
E /*/.:* $ 1*!%**
E /1!%:!5.* k'al<hr
2
E$cess air E ( +(
%
) $ 1**
(%1@(
%+
)
E 1/ $ 1**
(%1@1/)
E %**+
4heoretical air required E 1/ k" of air to urn 1 k" of oil
Actual mass of air requiredE 1/ $ (1 J %**<1**) k"<k" of oil
E /% k"<k" of oil
8ensile heat loss in the flue "as E m $ '
p
$ Q4
m E mass of flue "as
E /% J 1
E /) k"<k" of oil
'
p
E 8pecific heat of flue "as
E *.%)
Q4 E 4emperature of flue "as R Amient 4emperature
E )**
o
' R )1
o
'
E %.1
o
'
Heat loss E /) $ *.%) $ ()**@)1)
E /) $ *.%) $ %.1
E %.%*.:1 k'al<k" of oil
E %.%*.:1 $ /*/.:* Gcal<hr
E 1*!.*!5%* Gcal<hr
8ensile heat loss in the flue "as
as + heat loss to input ener"# E 1*!.*!5%* $ 1**
/1!%:!5.*
E %1.6 +
Heat "ained # comustion air E /% $ *.%/ $ (%**@)1)
E 1..).% k'al<k" of oil
E 1..).% $ /*/.:* Gcal<hr
E .6)%.).). Gcal<hr
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Bureau of Ener"# Efficienc#
11
Paper 2 - Set A Key
Heat "ained # comustion air
as + of input ener"# E .6)%.).). $ 1**
/1!%:!5.*
E 1..) +
L-2 e$,r+?e ?r+e*.y a)y t>3 3* the *3..3>+)#
a) Me,ha)+,a. @e-aerat+3) a)@ ,he-+,a. @e-aerat+3)
b) F"),t+3)$ 3* a $tea- trap
1) e$,r+?e the 3perat+3) 3* re#e)erat3r *3r h+#h te-perat"re *"r)a,e
A)
$
a) Me,ha)+,a. @e-aerat+3) a)@ ,he-+,a. @e-aerat+3)
In de@aeration! dissolved "ases! such as o$#"en and caron dio$ide! are e$pelled # preheatin" the
feed water efore it enters the oiler.

Me,ha)+,a. @e-aerat+3)
Dechanical de@aeration for the removal of these dissolved "ases is t#picall# utiliAed prior to the addition
of chemical o$#"en scaven"ers. Dechanical de@aeration is ased on 'harlesS and Henr#Ss laws of
ph#sics. 8implified! these laws state that removal of o$#"en and caron dio$ide can e accomplished #
heatin" the oiler feed water! which reduces the concentration of o$#"en and caron dio$ide in the
atmosphere surroundin" the feed water. Dechanical de@aeration can e the most economical. 4he#
operate at the oilin" point of water at the pressure in the de@aerator. 4he# can e of vacuum or
pressure t#pe.
Che-+,a. @e-aerat+3)
&hile the most efficient mechanical deaerators reduce o$#"en to ver# low levels (*.**1 m"<litre)! even
trace amounts of o$#"en ma# cause corrosion dama"e to a s#stem. 'onsequentl#! "ood operatin"
practice requires removal of that trace o$#"en with a chemical o$#"en scaven"er such as sodium sulfite
or h#draAine. 8odium sulphite reacts with o$#"en to form sodium sulphate! which is removed throu"h
low down. H#draAine reacts with o$#"en to form nitro"en and water. It is invarial# used in hi"h
pressures oilers when low oiler water solids are necessar#! as it does not increase the 498 of the
oiler water.
b) F"),t+3)$ 3* a $tea- trap
4he three important functions of steam traps are2
1 T 4o dischar"e condensate as soon as it is formed in the steam line < pipes.
%
3 T ;ot to allow steam to escape.
T 4o e capale of dischar"in" air and other incondensale "ases from the steam pipe.
c) Operat+3) 3* re#e)erat3r *3r h+#h te-perat"re *"r)a,e
4here are two sets of re"enerators consistin" of refractor# ricks. In one path! the flue
"ases flow heatin" up the chequered refractor# ricks on one side! while throu"h the
12
Paper 2 - Set A Key
other path! air for comustion flows which picks up the heat from heated chequered
refractor# ricks on the other side. 4he c#cle reverses with the time interval.
L-'
A heat e4,ha)#er +$ t3 ?e @e$+#)e@ t3 ,3)@e)$e the hy@r3,ar?3) =ap3r -+4t"re
*r3- a @+$t+..at+3) ,3."-) at the rate 3* 11/& 5#A$e, >h+,h +$ a=a+.a?.e at +t$
$at"rat+3) te-perat"re 3* 12&CC/ The .ate)t heat 3* ,3)@e)$at+3) 3* the
hy@r3,ar?3) =ap3r -+4t"re +$ 46& 58A5#/ The ,33.+)# >ater at '2CC +$ "$e@ +)
,3")ter-,"rre)t @+re,t+3) at the rate 3* 60 5#A$e, t3 ,3)@e)$e the =ap3r -+4t"re/
The $pe,+*+, heat 3* ,33.+)# >ater +$ 4/10 58A5#
3
C/ eter-+)e LMT a)@ area 3*
the heat e4,ha)#er $"r*a,e +* the 3=era.. heat tra)$*er ,3-e**+,+e)t +$ 66& 8A-
2
$CC/
Ans
Heat loss in h#drocaron vapour mi$ture E heat "ain in coolin" water
11 I /1* E 1: I /.1: I (4 R )%)
4 E 1%./ B'
&ater leaves the e$chan"er at 1%./B'
7D49 E (1%*@)%)@(1%*@1%./)<ln(1%*@)%)<(1%*@1%./)
7D49 of counter flow pattern E 66./ B'
H E mI'pI 4 E P I A I 7D49
1: I /.1: I (1%./ R )%) I 1*** E 11* I A I 66./
A E 11..) m
%
Area of the heat e$chan"er surface is 11..) m
%
L-4
A $tea- p+pe.+)e 3* 26& -- 3"ter @+a-eter & 1&& -eter$ .3)# +$ +)$".ate@ >+th
16& -- M+)era. >33. +)$".at+3)/ A$ a) e)er#y ,3)$er=at+3) -ea$"re% the
-a)a#e-e)t ha$ "p#ra@e@ the e4+$t+)# M+)era. >33. +)$".at+3) >+th e**+,+e)t
,a.,+"- $+.+,ate +)$".at+3)/
Ca.,".ate the e,3)3-+,$ +) ter-$ 3* pay?a,5 +* the +)$".at+3) +$ "p#ra@e@ at a
,3$t 3* 2& .a5h$/
G+=e)(
Operat+)# h3"r$ ( 0&&&
73+.er e**+,+e),y ( 01 D
F"e. O+. C3$t ( R$/ 46%&&& per
t3)
GC9 3* the *"e. ( 1&%2&& 5,a.A5#
Th+,5)e$$ 3* M+)era. >33. +)$".at+3) ( 16& --
Th+,5)e$$ 3* Ca.,+"- S+.+,ate +)$".at+3) ( 1&& --
S"r*a,e te-perat"re >+th M+)era. >33. +)$".at+3) ( 1& CC
S"r*a,e te-perat"re >+th Ca.,+"- $+.+,ate +)$".at+3) ( 66 CC
A-?+e)t te-perat"re ( '& CC
_________________________
Bureau of Ener"# Efficienc#
13
Paper 2 - Set A Key
Ans
Heat loss with Dineral wool insulation E U1* J (4s R4a)<%*V $ (4s R 4a)
E ( 1* J (6* R )*)<%* V $ (6* R )*)
E /:* k'al<hr per 8quare meter
Heat loss with 'alcium silicate insulation E ( 1* J (11 R )*)<%* V $ (11 R )*)
E %:1.%1 k'al<hr R 8q. m
8urface Area with Dineral wool E ).1/ 9 7
E ).1/ $ *.11* $ 1** E 16%.6 8quare meter
8urface Area with 'alcium 8ilicateE ).1/ $ *./1* $ 1** E 1/1.) 8quare meter
Heat loss with Dineral wool E /:* $ 16%.6 E :%:5. k'al<hr
Heat loss with 'alcium silicate E %:1.%1 $ 1/1.) E )56/1 k'al<hr
(:%!:5. @ )5!6/1) $ :!*** $
/1!***
1*!%** $ 1*** $ *.:6
Annual savin"s E
E ?s. 16.1 7akhs < #ear
Pa#ack period E %* < 16.1
E 1.1/ #ears E 1).6 months
L-6 The e)er#y *.3> @+a#ra- +) a ,3#e)erat+3) p.a)t +) paper +)@"$try +$ #+=e)
?e.3>/
14
Paper 2 - Set A Key
Ca.,".ate the *3..3>+)#
i) I)p"t ,3a. ,3)$"-pt+3) per h3"r +* *ee@ >ater te-perat"re +$ 6&
3
C
ii) 2eat t3 p3>er rat+3 3* ,3#e)erat+3) p.a)t
iii) D t"r?+)e a)@ #e)erat3r .3$$e$
Ans Input coal consumption E HE1*!*** $(66*@1*) < (*.: $ /***) E11.%1 4ons< hr
Heat to power ratio E (1*!*** $ ..*) < (/.** $ :.*) E :.)/
4urine and "enerator loss E 1**** $ 66* R(/.** $ :.* J1*!*** $ ..*)<1*
.
E 1.1//
Dillion k'al
+ loss E 1.1// $ 1*
.
$ 1** < (1*!*** $ 66*)

E/+
L-E L+$t @3>) a)y te) p3+)t$ that )ee@ atte)t+3) >h+.e $e.e,t+)# ?+3-a$$ *."+@+$e@
?e@ ,3-?"$t+3) ?3+.er
4he followin" areas need attention with iomass fed oilers2
Pneven spreadin" of iomass fuel on oiler "rate can lead to secondar# comustion in the
super@heater Aone! resultin" in overheatin" of super heater tues and fluctuations in steam
pressure.
,requent erosion of super@heater and economiAer coils can occur! due to hi"h silica content
in the iomass! especiall# in rice husk.
Hi"h e$traneous matter in iomass (sand and mud) causes tue foulin" and fluidiAed ed to
e drained more frequentl#! with resultant heat loss.
'aron and dust coatin" of oiler tues results in lowerin" of steam temperatures!
especiall# durin" soot lowin".
Presence of Pesticides (used durin" farmin") adds to tue failure frequenciesK mainl# due to
potassium constituents.
'orrosive constituents in iomass adversel# affect oiler internals! especiall# the super@
heater tues. 'hloride content in certain t#pes of iomass (like cotton stalk! :R5+) can comine
_________________________
Bureau of Ener"# Efficienc#
15
Paper 2 - Set A Key
with sodium and potassium in hi"h temperature re"ime to a""ravate the corrosion process.
8ome oilers which use ?ed =ram husk<twi"s as fuel pose corrosion prolems at the cold
end (i.e.! secondar# super@heater and economiAer tues)! due to the sulfur content.
4he iomass fuel mi$ fed to the oiler! in quite a few cases! contains a comination of . to 6
iomass t#pes. Each iomass has a separate air@to fuel ratio! and it is difficult to set a workale
airRfuel ratio.
Hi"h moisture content in the iomass causes frequent Lammin" of the fuel in feeders!
leadin" to fluctuations in steam pressure and temperature.
Hi"h moisture content in the iomass also leads to plu""in" and chokin" of closel# spaced
heatin" surfaces. 4his situation is further a""ravated # the super@heater tue coil with ver#
close spacin"! often the result of a desire to achieve a compact desi"n.
9ue to iomass fuel siAe variation! occurance of unurnts in flue "ases and ottom ash is
hi"h! resultin" in lower efficienc# and also variation in steam pressure and temperature.
Asence of iomass feed rate measurement mechanism leaves little room for accurate
assessment of heat rate<efficienc#. Providin" a wei"hin" mechanism is difficult on account of
different iomass fuel cominations ein" used! with different (and low) ulk densities.
9e"radation of iomass durin" stora"e in e$posed amient wet atmosphere leads to loss of
heat value. 7oss of material due to winda"e and carpet loss! coupled with loss of heat value on
account of deca# (inherent iomass characteristics)! can cause an error in assessment of input
fuel ener"# (as the input heat is customaril# evaluated ased on received iomass quantities
and ='>).
------- End of Section - III ---------
16