EEE Use/ul for all Indian state Viva-Vice Preparation & Fresher Engineer MITHILESH SINGH Os oth nui kad erste) eased nd eee Bil 608 (OIL ERIOPERATIONIENGINEER)IBE IN MECHANICAL ENGINEERING] BIBUOMANIN' ELECTRICAL ENGINEERING THERMAL POWERPLANT ENGINEERING (NPTI)Preface Energy is the primary need of any human being now a days. Development of any country lepends upon the development of its Power Generation sector. Boiler Engineering is the area where improvement scope, innovation and system improvement are available all the time. Looking the difficulties of candidates who are going to appear in 1st Class/2nd Class Boiler attendant mination or going to appear in BOE (Boiler Operation Engineer) viva-vice Examination, | had ided to guide them and provide a guide book by which the candidates can take the benefit getting some tips of our experience in this field. | got opportunity to work at different Power Plants at different levels, | always believe that ia need to be safe,smart and skill. To full fil this objective we have published this book. re facing any Boiler related interview/Viva-vice examination, candidate needs to be men- prepared for such examination. Boiler Engineering is very broad area where the possibility inuos learning, teaching, training & skill development is a part of life. This book is pre- in such a way that candidate can get all the vital resources for preparation of Viva-vice mination. There may be some typographical or technical error in this book. | request All the Reader’s ive their valuable feed back to make this book error less in future. | am fortunate to work with iny excellent mentors who shaped me to grow my knowledge and always suggested and ported me in the right direction. | specially thanks to Shri Vinay Shandilya Sir, Shri Umesh hra Sir & Shri Nishant Bajpai Sir for their support and guidance. My wife Mrs Shaivalini Singh, my daughters Smriti Singh & Ritika Singh sacrificed a lot for as. | have not given enough time for them. Thanks for all your understanding, support and ifices. Thanks to my colleagues, friends and critics who encouraged me to write this book. Most me to alll for your kind suggestions to make this book error less in future. Mithilesh Singh\ List of Content S.N.| Name of the Chapter Page 01. | Introduction & strategy about Viva-vice Examination 56 02. | Boiler Engineering technical Question & Answers 7-29 03. | Boiler & Turbine trip, protection & interlocks 30-35 04. | Boiler Emergencies 36-40 05. | Standard Operating Procedure of Thermal Power Plant 41-49 06. | Routine/Schedule checks in a Thermal Power Plant 50-56 07. | BR Act-1923 (IBR Regulations-1950) 57-63 08 | Energy Efficiency in Thermal Utilities 64-65 09 | Basics of Boiler Engineering 66-70 10. | Metallurgy/Boiler tube Failure 71-78 11. | Water Treatment in a Thermal Power Plant 79-88 12. | Instrumentation in power plant 89-93 13. | Emission control device & Ash handling System 94-99 14, | Boiler erection & commissioning activities 100-104 15. | Duties of Boiler attendant & Boiler Operation Engineer 105-108 16. | Boiler Engineering Glossary 107-124 17. | Important diagrams 125-132 133-136 ‘Success tips for personality developmentIntroduction &strategy about Viva-vice Examination ‘4st Class/2nd Class Boller Attendant or BOE (Boiler Operation Engineer) Viva-Vice Examination is the ver- 1. examination by which interviewer try to understand your practical approach, safe working practices, willing- hess to do standard working pattern and your emergency handling capability. Interviewer never expect you to give ithe answer but necessary thing Is that the answer given by you is how much realistic and accurate. They never ked beyond the boundary of your plant premises. They will ask all the question inside your plant periphery. 18 itis important that your answer belongs to your plant and your system. + What is Boller Viva-Vice Examination: Boiler Viva-Vice Examination is the test where interviewer will evaluate following things Your technical knowledge. Your practical depth. Your emergency handling approach. Your SOP(Standard Operating Procedure) aware- ness. Your awareness about IBR( Indian Boiler Regula tion) Act-1923 (Regulation-1950) ‘Your swiftness about plant safety. Your management/Communication ski. Your behaviour, punctuality atitude &disciptine, Your confidence level What you have to do for better preparation of Viva-Vice Examination: You have to do following preparation simulta- neously. Technical knowledge enhancement : Increase your technical knowledge (theory, practical, equip- ‘ment permissive, interlock protection,alarms and trip value of Boiler, Turbine & Generators of your ‘own plant) Group discussion participation : Your have to participate in all technical group discussion and interact with seniors, peers, subordinates. Standard Operating Procedure aw You have to aware about your plant light- up,shutdown,Emergency handling, plant tripping normalization & Plant Black-out restoration pro- cedure in detail. you also have to be aware of plant safaty procedures. about day to day plant operational activities like, ‘gauge glass charging, valve opening/closing/soot blowing/Blow down/safety _checks/ ‘equipmenthealthiness check (sound, heating! vi- bration of bearings) various auxiliaries starting stoppagelchange-over etc. 1 2 3 4 5. 10. n. 12, IBR rules awareness : You have to study IBR Book special attention on Reporting, Authorities, IBR terms & definitions, Boiler renewal, accident reporting, maintenance activities of pressure parts ‘of boiler). Energy Efficiency awareness : Your engage- ment in Energy management system how to run your boiler/turbine/generator efficiently. Appoint your mentor : You have to appoint suit- able mentor for your appropriate guidance. Personality development : Improve your body language as well as your confidence level. En- hance your communication skis and your way of presentation. Looking to cover of all above topics, chapter wise description given in this book. 4.3 : Precautions during going at the desk of Viva-Vice Interviewer: You have to take care about following things be- fore going at the desk of Viva-Vice Interviewer. You have to be stress free. Your dress must be neat & clean. Your shoes should be polished. Before entering at the desk take permission. Before leaving the desk say “Thank you very much sir” ‘Answer only the question whose answer you know better. Dont try to give complex answer, like mixed up cof so many different task Your answer has to be to the point. Try to give the answerin your mother tongue, take the prior permission if answer other language in which language question is asked. Your mobile has to be switched off before enter- ing at the desk. You have to bear all your qualification documents during viva. Don't try to be over smart or intelligent.Boiler Attendant & BOE Exam Viva-Vice Preparation 13. Viva-Vioe interview i usta formal procedure to know about you practical approach durin Boller operation, Nence answer should be simple and straight 14. Your answer must fl fl the coverage as ques- tion asked yo, 15. Better way to bring interviewer in your strong area, where you can answer much better than tough area in you opinion, 1.4: Few Personnel questions which may asked during viva vice examination: Before replying the answer of any personnel ques- tion, which is asked during viva vice examina- tion, you have to be mentally prepared and well aware about the impact of that question on inter- viewer. Following personnel question may be asked dur- ing viva vice examination. 1. Were are you working right now. 2. Whatis the plant capacity. Noma 0. "1 12, 13, 14 15. 16. 17 18. 19. 20. What is your qualification. What is your family background. From where did you completed your education. What prevention you take during night duty. What is the communication system during shit plant operation, Tell us about the overview of your plant. What is your routine activities of day to day. What are the PPE(Personnel protective equi ments) used during duty time, Have you faced any accident condition dur plant operation, Who is your reporting officer. How you doing relieving of your shift. What is your reporting pattern. What is the initial checking during of your shi starting, Any frequent failure of steam line, ‘Any abnormal sound during soot blowing, What is the emergency contact reference nu ber of your plant. What is your most favourite topic. What major risky area in your plant NOTE : RELATED TO YOUR PLANT. DURING REPLY OF ANY OF ABOVE QUESTION, YOU HAVE TO TELL HIM REAL FACTSDuties of Boiler attendant & Boiler Operation Engineer 15.1 : Duties of any Boiler attendant (1stClass/ 9. Class) : 10. Legal authority of 2class boiler competency ieate holder:Second class boiler competency (At 11 Mant) certificate holder is authorized to havecharge 12. fasingle boller of any type the heating surface of which snot exceed 240sq.meters. He may, however, at- Wd to a battery of boilers (max. three) and (i) gateheating surface not exceeding 140 sq.meters, (li) vided he is assisted by fireman. (No. offireman re- das per consideration of chief Inspector) (iy Legal authority of 1"class boiler competency (iv) ficate holder: First class boiler attendant is autho- Bed tohave charge of single boiler of any type orcapacity 1, lwo or more boilers in a battery or separate, the total ing surface of whichdoes not exceed 700 sq. meters. Biided that such boilers shall be situated within a fiusof 23 meters in the same premises and belong to 2. ‘owner and then he is assisted bynecessary sec- class boilers attendants, 3, Duties & responsibilities of any Boiler atten- (1st Class/2nd Class) : 4, Operate high pressure boilers, including starting 5. ‘and shutting down. 6 Monitor boiler operations and reactto varyingload 7. requirements, 8. Perform constant visual checks, read gauges, and manipulate controls. Assure that various meter readings of pressure and temperature are recorded, Inspect boiler pipes, valves, pumps, and safety devices for leaks and malfunctions. Periodically inspect and adjust control mecha- nisms. Blow down boiler when conductive solids and im- purlies exceed specified limits; test high and low pressure safety controls. Schedule and supervise cleaning of equipment ‘and work areas. ‘Supervise and assist in minor equipment repairs. May supervise daily maintenance on boilers in- cluding oil and greasing of bearing of fans, mo- tors, and other operating mechanisms. Observe fire and safety precautions. May be responsible for chemical makeup of wa- ter, testing of water qualities, and checking vis cosity of cil, including: ‘Adding chemicals to condition boiler water. Maintaining @ chemical balance in boiler water according to prescribed procedures. Performing conductivity, alkalinity, phosphate, sllica, sulphate, and other hardness tests. ‘Adding chemicals to boilers needed to maintain a good chemical balance. Prepare and maintain records on treatment, oil, gas chemicals consumption, and steam . Coop- erate and work with State and other inspectors as required. May perform general maintenance duties requir ing skills in plumbing, painting or mechanical team members. May investigate and take corrective action for ‘emergency repairs, Perform other related duties as assigned. ‘Supervise the manpowerlworkers for routine work. Ensure pollution free environment at work place. Reporting to seniors if any consultation required. Conscious about any abnormal sound in area. 15.2 : Duties of any BOE (Boiler Operation Engineer) : "BOE (Boiler Operation Engineer)’ means a person granted with a certificate of proficiency as a boiler operation engineer under the IBR rules. Boiler Operation Engineer holding a Certificate of Proficiency under IBR rules shall, at all reasonable times during the period any boiler isin his charge or attendance, be bound to produce such certificate when called upon to do so by any of the persons empowered under section 15 to call for the production of a certificate or provisional order granted under the Act.Boiler Attendant & BOE Exam Viva-Vice Preparation Where Boiler Operation Engineer is Required ? The owner of ASingle boiler or Two or more boilers connected in a battery or \ Many separate individual boilers situated in a radius of 50 meters having a total heating surface & \1000 sq. meters shall not use the same or permit the same to be used unless the boiler or bolts in direct charge of a certified Boiler Operation Engineer. Duties & responsibilities of any Boller Operation Engineer(BOE) Safe and reliable operation ofthe entire Boiler. Oversee the functioning of incharge of the shift. Handling emergency condition ike aunilary tripping, plant tripping, black out or any accident Toconserve fuel and efficient use of steam, the boiler using industries started installing high press Ustize technical skill of as an operating personnel. 4 Observe fire and safety precautions, ‘ Routine checks of all mounting and ftings of boiler. Take hydraulic test of boiler whenever required, Timely correction of any abnormalities in any part of vessel Follow rules and regulation of IBR Act, Routine checks of supports and structure of boiler. Give the training to the subordinates, Timely reporting to his seniors Timely communication & followup with Boiler Inspector/CIB. He is authorized to do annual inspection of any land boilers.Success tips for personality development \ 18.1 : Success Tips to improve your body Lan- guage 1. Don’t cross your arms or legs ~ that you have probably already heard you shouldn't cross your, arms as it might make you seem defensive or guarded. This goes for your legs too. Keep your arms and legs open. Have eye contact, but don’t stare — If there are several people you are talking to, give them all ‘some eye contact to create a better connection and see if they are listening. Keeping too much. eye-contact might creep people out. Giving no eye-contact might make you seem insecure. Don't be afraid to take up some space ~ Tak- ing up space by for example sitting or standing with your legs apart a bit signals self-confidence and that you are comfortable in your own skin, Relax your shoulders — When you feel tensed it, easily winds up as tension in your shoulders. They might move up and forward a bit. Try to relax. Try to loosen up by shaking the shoulders a bit and move them back slightly. Nod when they are talking — nod once in a while to signal that you are listening. But don't overdo it and peck like Woody Woodpecker. Don’t slouch, sit up straight — but in a relaxed way, not in a too tense manner. Lean, but not too much ~ If you want to show that you are interested in what someone is say- ing, lean toward the person talking. If you want to show that you're confident in yourself and relaxed lean back a bit. But don't lean in too much or you might seem needy and desperate for some ap- proval. Or lean back too much or you might seem arrogant and distant Smile and laugh ~ lighten up, don't take your- self too seriously. Relax a bit, smile and laugh ‘when someone says something funny. People will be a lot more inclined to listen to you if you seem to be a positive person. But don't be the first to laugh at your own jokes, it makes you seem ner- 10. 1. 12, 13, 14. 15. 16. vous and needy. Smile when you are introduced to someone but don't keep a smile plastered on your face, you'll seem insincere. Don't touch your face — it might make you seem nervous and can be distracting for the listeners ‘or the people in the conversation Keep you head up - Don't keep your eyes on the ground, it might make you seem insecure and a bit lost. Keep your head up straight and your eyes towards the horizon. ‘Slow down a bit ~ this goes for many things. Walking slower not only makes you seem more calm and confident, it will also make you feel less stressed. If someone addresses you, don't snap you're neck in their direction, turn it a bit more slowly instead. Don't fidget — try to avoid, phase out or trans- form fidgety movement and nervous ticks such as shaking your leg or tapping your fingers against the table rapidly. You'll seem nervous and fidget- ing can be a distracting when you try to get some- thing across. Use your hands more confidently — instead of fidgeting with your hands and scratching your face use them to communicate what you are trying to say, Use your hands to describe something or to ‘add weight to a point you are trying to make. Lower your drink —don't hold your drink in front of your chest. n fact, don’t hold anything in front of your heart as it will make you seem guarded and distant, Lower it and hold it beside your leg instead. Realize where you spine ends ~ many people (including me until recently) might sit or stand with a straight back in a good posture. However, they might think that the spine ends where the neck begins and therefore crane the neck forward in a Montgomery Burns-pose Don't stand too close -one of the things we learned from Seinfeld is that everybody gets weirded out by a close-talker. Let people have their personal space, don't invade it.Boiler Attendant & BOE Exam Viva-Vice Preparation 17, Mirror - Often when you get along with a person, when the two of you get a good connection, you will start to miror each other unconsciously. That means that you mirror the other person's body language a bit. To make the connection better you can try a bit of proactive mirroring Keep a good attitude — last but not least, keep a positive, open and relaxed attitude. How you feel will come through in your body language and can make a major difference. For information on how make yourself feel better read 10 ways to change how you feel and for relaxation ty A very simple way to feel relaxed for 24 hours. 18.2 : Ten Tips to boost your confidence : Don't put yourself down Don't apologize for being you Be decisive don't say may be. Say yes or no Don't say | can't instead say, may be I can I'lltryit Don't procrastinate (postponing) Think about your positive points Volunteer more often Dream a little Set Goals. Play the part 18.3 : Increase Your Self-Control in 5 Steps It takes self-control in order to reach your goals. You increase it the same way you beef up your self- confidence, by mastering smaller steps one at a time, and building up trust in yourself. Step One: Making the Commitment You'll find your goals are easier to reach once you can focus on them in your mind. What exactly do you want todo? What - exactly - are the steps needed to take you there? It’s easy to say you want to live a healthier life, but you won't accomplish anything by trying to cover everything at once. Look at your current abilities, and what you're able to tackle right now. Using your strengths, how can reach your overall goal? Eating more Vegetables? Cutting down on smoking? Exercising with friends? Pin down your goal and focus your efforts on taking manageable steps in that direction. Step Two: Put it in Writing Making a commitments alot like making a map, It's easier to follow your decisions when you've laid them down on paper. When you can see your plan, when you have a chance to check items off one by one, you feel Powerful and in control of your situation. Writing things down strengthens you focus, and gives you a reminder of what you have to work on. Step Three: Kick into Action Start once you make your commitment. Ifyou walt for the next day, or the next week, or after the holidays, ete you will keep coming up with reasons to avoid start ing at all. Worse, you'll find reasons to stop midstream, If you find yourself tempted, it may be a sign that your baby steps aren't small enough. “Never drinking pop ever again” may work for someone who drinks @ very small amount, but for someone who lives on ca bonation, it's not realistic. Remember, self-confid people honor their abilities and know their limitato They don't set themselves up for fairly. Be good to yo spirit by setting goals that won't drag you off-course. Step Four: Let the Daydreams Beg Motivation fuels your efforts. Daydreams fuel your vation. Take some time today to imagine your succes ‘See yourself drinking bottled water, or chewing on g instead of taking a drag. Envision your thinner thigh sparkling white teeth, Most importantly, see smiling. While visualizing the life you want to lead powerful tool in creating the self-confidence, you also use visualization techniques to fight off nega thinking. The next time stresses come to call, eyes for a moment and breathe deeply. Imagine self walking into a blooming garden. Stop in rose bush, litered with vibrant blooms and witing Put on your garden gloves, and pick up your then stop to smell the roses. With every sniff brant bloom, here the whispering positive me your mind. "You can do this.""You will re goals.""You deserve your success.” The willed have an acrid smell, and whisper negative co Snip them off the bush before they have t ‘say, but them in your basket and once back‘ fice, throw them away.Boiler Attendant & BOE Exam Viva-Vice Preparation Step Five: Celebrate Your Succ However little they may be, make a display when your plans reach fruition. It takes focus, commitment, and effort to make even the smallest baby step tum out. Take a moment to feel proud of yourself and realize that improving your life isn't 3p tough. You may even want to reward yourself when you reach certain milestones, but be careful. You want to make progress for yourself, not for the latest CD or a new watch. Sticking to your goals isn’t so much about willpower as itis making your choices realistic, and aligning your actions with your overall purpose. Be forgiving, hopefully, and celebrate your successes. Soon you'll be living the life that you want, and you'll have the trust that you need to meet future obstacles head on, 18.4 : Develop your confidence Few helpful tips to build self confidence one success at atime. Make a list of your strong points& make a strategy of it to keep it strong forever. Choose two of those things that you want to work on to improve even more. Exude confidence even if you do not feel like it. Look at yourself in a different way than you are used to doing Note : If you have a set-back do not let it get the best of you. Remember the times when you exhibited self confidence and how good it felt and then try again and each time will help you to build confidence and confidence building will become a way of life,About the Author n= 18 il, Mithilesh Singh 5 DGM-Power Plant (GPIL-Raipur) Sr. Advisor-IBCS (Indian BOE Coaching Services] Certified Energy Auditor [EA-27560] BOE(Boiler Operation Engineer) BE in Mechanical Engineering Diploma in Electrical Engineering ~ Thermal Power Plant Engineering(NPTI) Mr. Mithilesh Singh has invested over more than 20 years in Industry and gained rich experience in power sector.He has started his career from M/s. Hindustan Aeronautics Limited (HAL) Amethi. He is double Intermediate (Mathematics & Biology groups) from UP Board Allahabad. He has taken SOOMW Simulator Training from NPTI Faridabad (Haryana). His unique combination of skill set and experience helps him in creating a collaborative environment between industry and Academia. He believes in thinking out of the box and has a spark to Perform beyond expectations. His teaching technique, explaining methodology, friendly behaviour along with communication skills is excellent. He started advisory for BOE coaching since year-2011 Comprehensive operation & maintenance of the Thermal power plant is the main functional area of his career. He is well aware about IBR[Indian Boiler Regulations], CDM[Clean development mechanism], REC[Renewable Energy Certification], EMS[Environment Management System], IMS[Integrated Management System] & PAT[Perform achieve & trade]. Teaching is not a profession of Mr. Singh, but also a passion to make the career of power engineering professional. He always updates himself and believes in compiete competence. He believes in “3-S[SAFE,SKILLED & SMART] INDIA". He has written thisbooks for Boiler viva vice examination for BOE(Boiler Operation Engineer) & Boiler attendant(First Class & 2” Class), which is helpful for welcomes all your suggestions to make this look erroless students of all states across india. | Contact details of Author : Mobile No : +91-9827482029 E-mail : mithileshkhudawal@gmail.com Facebook:https://www.facebook.com/MithileshIBCS/