Indian BOE Exam Guide Book (Edition-1) 1*' Edition 1" Nov-2014 Indian BOE Exam Guide Book MITHILESH SINGH Certified Energy Manager BOE(Boiler Operation Engineer) Bachelor in Mechanical Engineering Diploma in Electrical Engineering NPT! in Thermal Power Plant EngineeringIndian BOE Exam Guide Book (Edition-1) Preface India is suffering from huge energy crises & need very broad sense of tackle energy security in upcoming days. Government of India has been establish SDA(State designated agency) in each state of India to enhance the energy performance of energy generation & consumption sources as well as to promote renewable energy sources. Looking the ‘scenario of energy crises it is most important that to adaptation of energy efficient technologies , up gradation of existing energy consuming appliances, awareness of energy utilization in people ,optimization of wastage of energy equally most important contribution in Indian industries to improve the performance of energy saving & conservation. | am going to publish this book with great inspiration & encouragement by Shri Vinay Shandilya & Shri Nishant Bajpai. The concept to write this book is got from my dedication toward nation because | feel that | should contribute my skill toward nation in some one field in which | can do much better. So many ideas received by me when more than 50 student successfully achieved the certification of Boiler operation Engineer under my guidance across the India. | realize that my skill can enhance the technical skill of India as well as availability of huge pool of skill engineer across in India to widely acceptance of my concept 3-S(Safe, Skilled & Smart) India . | have covered the content as per New BOE syllabus (amended in July- 2011) . In BOE written examination most of the student could not succeed because of unavailability of competent study content in a single book. | personally feel that this book will set a new mile stone in the field of Boiler Engineering in India. Boiler Engineering is a mixed filed of Thermal ,Electrical & Mechanical Engineering, Whether | belong to all three field which may be an unique combination of theory. | appeal to all of you that kindly give your valuable suggestion to improve this book for further enhancement of study content. | shall re-edit this book in future also for latest & upgraded version as per New syllabus of BOE Examination. | thanks to Shri Satya Prakash Singh(MA & M Phil in History, 1* place in Pt Ravi Shankar University Raipur ) to their extended support . Thanks to my friends, students, colleagues, seniors & followers who encouraged me to write this book. MITHILESH SINGH +91-9827482029fiIndian BOE Exam G le Book (Edition-1) CONTENT LIST Part it Name ‘Name of the topics Page No | Total Pages ‘Ai, Ailindia BOE Examination Syllabus i Syllabus, Guideline [772 BOE Examination preparation guideline z A Formulae & | | A/3. Boiler Engi Formul 3 * Numerical Erercise oiler Engineering Formulae ‘Ala, Numerical Exercises 7 ‘B71. Precaution to be taken while inspecting any Boller i B/2. FUELS 5 B/3_ COMBUSTION OF FUEL 8 1/4. DRAFT SYSTEM 9 (BIS. TYPES OF BOILERS - 10 'B/6. Precautions to be taken for starting a boller and 1 economizer from cold and banked (hat) fire condition _| BIT. Need for periodic cleaning into the Boiler 2 B/8. Economizer 12 Boller Engin 'B/9. Boiler Scales Preventions [12 B | Theory (Paper-1 B/10. RLA(Remnant life assessment) Test 14 54 B/11. Basios of Boiler Engineering 15 B/12. Basics of Strength of Material 31 8/13. Some alloys and theit composition 36 8/14, Basic Boiler Construction 36 'B/15. Root causes of boiler failure a2 B/i6. OBSERVING BOILER SAFETY RULES 45 8/17. The Metalluray of Boilers a7 B/18. Guide for proper drainage and layout of steam ines | _51 B/19. Air preheater(APH) 51 20. Boiler preservation 54 ii. Engineering drawing preparation basic guideline 1 C/2. Major type of steam traps 2 Engineering _|C/3. Boiler Mountings 4 Cc Drawing C/A, Boller Accessories 3 3 (Paper-3) C/5. Pipe Supports 10 C/6. Engineering Drawing related Question & Answer = 5 Ci7. Symbols 19 (C/8, Assembly drawing 23 D/.IBR Terms 1 IBR Terms, Q&A & | D/2. Boller Engineering small Q&A 4 D Glossary /3. Boiler Engineering medium Q&A 12 84 D/4. Boiler Engineering long Q&A 58 /S. Boiler Engineering Glossary 64 ice [E/1. Thermal Engineering MCQ (160 Nos.) 1 Questions {wede) | ©. Boller Engineering MCQ (242 Nos) 13 E 11395 Nos] 6/3. Power Plant Engineering MCQ (300 Nos) 58 151 4 E/4. Thermodynamics MCQ (312 Nos.) 34 EI. Engineering Drawing MQ (321 Nos.) 140 F | Snaps & Diagram | 7. Boler Engineering related dagram & snaps 1 30 G Success Tips | &/* Success Tips 7 7 Total 4581PART-A [Syllabus ,Guideline, Formulae& Numerical Exercise] 1 A/1.ALL INDIA BOE EXAMINATION SYLLABUS A candidate in order to be qualified fora certificate of proficiency under these rules, shall inter alia, satisfy the ‘examination that he- wri Paper jlor Engin (a) Can calculate loads, area, volumes, quantites and weights; {b) Can give description ofthe principle types of steam boilers used on land and to state the purposes and reasons for which cifferent types of boilers are employed; and from the data and formulae supplied, calculate the safe working pressure for any part of a boler in accordance with the IBR: (©) Can calculate the direct stress, the torsional stress and the bending stress in found bars and shafts and the bending stress in ractanguiar bars and levers with given load (@) Understands the working and management of steam boilers, super heaters and economizers: (©) Understands the use and purpose of various valves, cocks, mountings fitting and other safely devices: () Can give a description of and explain the functions of feed pumps, feed injectors, feed regulators, feed water fiers and softeners, feed heaters, air heaters, clarifiers, steam accumulators, forced draught, induced draught, and automatic draught contra! devices; (g)_ Can answer question on fact relating to combustion, heat and steam an calculate consumption of coal and water and quantity of steam that may be generated from a given heating surface under the various systems Of draught, in any land boilers and also calculate the averall of boiler plant (h) Can explain jet and surface condensation, reheating and the working of steam expansion’ Witten Paper No.2 (Boller Engineering-l)) (}) Can explain the general methods employed in laying foundation for boilers and chimneys and the suitable _area and height of chimneys to promote efficient combustion (Can explain the significance of principal appliances in use for the prevention of smoke and the principle on Which they work and give description ofthe principal mechanical stokes, pulverizes, gas, oll and pulverized fuel system in use: (K)_Understands the need for periodical cleaning, the methods used for prevention of scale ar other deposits on heating surfaces and the necessity for maintsining a certain pH value in feed water, (1) Can detect defects in boilers and state the means and methods of rectifying them: (m) Understands the precautions to be taken for starting @ boilers and econom:2et from cold of from banked fire condition (n) Understand the procedure to be adopted in putting an economizer out of commission while the boiler is on steam; (0) Can explain the methods adopted for the achievement of fuel economy anduse of varus instruments use in @ Boller House, (p) Materials used in Boiler components and piping; and Paper No.3 (Boller (@) Can read and prepare @ working sketch and drawing of boiler of boler mounting or pats thereof ns pertaining to Boil ices) {An ral examination to answer questions pertaining to Boiler Practices. ‘A Candidate shall secure at least 45% of marks in each written papers as wel as in oral & drawing ‘examination but the aggregate should not be less than 50% of the total marks in order that he can be: awarded a certificate of proficiency, Indian BOE Exam Guide Book (Edition-1) Author : MITHILESH SINGH, mobile: +91-9827482029, EmailPART-A [Syllabus ,Guideline, Formulae& Numerical Exercise] 2 A/2, BOE Examination preparation guideline _ “Subject Name Boiler Engineering- 1 (Paper-1) 2 (Paper-2) General guideline for preparation Question may be ask on following types 1, Numerical Question-Review all the numerical exercise of Part-A 2.Multiple choice question(MCQ)-Study entire MCQ of Part-E 3, Subjective type — Kindly refer Part-B, D&F Engineering Drawing (Paper-3) Engineering drawing preparation guideline:-- "FOR ASSEMBLY DRAWING IT IS MOST IMPORTANT THAT YOU SHOULD DO YOUR PRACTICES REGULARLY" 1, Assembly drawing :Assembly drawing is basically practice base preparation, hence do your practices for all the below mention types of valves. Sprayed part list be assembled to prepare a complete assembly drawing of a valve. Always draw the assembly drawing from lower to upper side. First you draw center tine. From starting draw from bottom left half and right half section parallelly . Valve parts will fit on sequencing order. During the practice time you must refer the serial number of the part fitting in place of assembled view. Scale ratio is most important to draw any assembly drawing. Hence you should decide your scale ratio as per drawing sheet. !t will be much better if you try to compiete your assembly drawing within a time limit (about within 2 hours) in a single attempt (no any gap of time to complete the assembly). Initially t will take time but when you will do your practices your time will be consequently reduced 2. Remember all Valves & welding joints Symbol. 3. Isometric to Orthographic (front, side & to view) & vive-versa 4 Free hand sketch for different part of schematic diagram of boiler steam & feed water scheme of your plant. 5. You may also attentions on basics of drawing (ie. fil in the blank, orthographic drawing & parts name of valves). Kindly note that All seven valveParts name & MOC (material of constructions) should be remember on your fingertips. Viva-vice Examination(Verbal) Following are the basic guideline for your BOE examination Viva-vice preparation, question may ask in viva on the following topics hence do your preparation accordingly: 1, Basics of Boiler Engineering (Thermodynamics related question) 2. Metallurgy of Thermal power plant. 3, Basics of valves & their use of application. 4, Welding technology (Types of welding, welding defects, uses & different welding rods application), 5. Water treatment in power plant (Pretreatment, D M plant schemes, chemical uses & their cause of utility). 6. Emergency handling during any abnormalities. 7. Boiler light up procedure (Cold/Hot). 8. Boiler protection & interlocks. 9. IBR (Indian boiler regulations) related question, 10. Checking of your presence of mind/confidence level on all above topics. PART-G will enhance your confidence level to face viva-vice examination. Author : MITHILESH SINGH, mobll BOE Exam Guide Book (Edition-1) -91-9827482029, Email : mithileshkhudawal@gmall.comPART-A [Syllabus ,Guideline, Formulae& Numerical Exercise] 3 A/3.Boiler Engineering Formulae: 4. Units of Measurement Data: Absolute pressure = Gauge Pressure + Atmospheric Pressure = Atmospheric Pressure - Vacuum Pressure = P= 1X g X h(71 (water) = 1000 kglm3, I (Mercury) = 13596 kgim3) Specific Gravity of Mercury = (Density of Substance/Density of water) = 13596/1000 = 13.596 Water at Atmospheric Pressure: Freezing point = 0°C, Bolling Point= 100°C NTP (Normal Temperature and Pressure) Atmospheric Pressure = 760 mmHg; Temperature = 0°C. STP (Standard) Pressure = 760 mmHg; Temperature 15°C Molar (Universal) gas constant = Ro = 8.3143 kJ/kg"Kmol = MR = Molecular weight X 0.287 kd/kg’K (For Air) Air=>Cp = dhidT = 1.005ki/kg"K, Cv = Ri(") - 1) = 0.718kJ/kg"K, 1 = Cp/Cv = 1.4; R= Cp-Cv = 0.287ksikg"k For Copper, Cp = 0.394 kJikg"K Conversion’ 1 kg/em2 = 10 m of water column = 10000 mmwc = 10000/13.596 = 735.81 mmHg (mm of Mercury) 1 bar = 750 mmHg = 1.0197 kg/om2 = 10197 mmwe = 100000 Pascal = 100000 Nim2 1 Atmospheric Pressure = 760 mmHg = 1.0333 k/cm2 = 10333 mmwe = 1.0133 bar “C= K~ 273.16 = (5/9)X("F-32); °F = °R- 459.6 = (9/5)°C + 32, (O°; O°C = 32°F; O°F = -17.8°C; 100°C = 212°F }000cmS ; 1 m3 = 1000 Litre = 1000000em3 foot = 0.9144 m; 1 mile = 1760 yard = 1609'm: 1 acre = 43860 sq. Foot 1 Lb = 0.453592 kg: 1 in = 25.4 mm; a kof = 9.81 Newton; 1 Lof = 4.448 Newton: 1 bai ‘n, 4.505 Lbi/Sq 2. Properties of Gases Laws: Boyle: PV = C (T=Constant) => P1V1 = P2V2; Charles: VIT = © (P=Constant)=>Vi/T4 = V2/T2 Combination: PV/T = C = PIV1 /T1 = P2V2 /T2 => PV = mRT Real Gases (Van der Waal's Equation) (P + 8lV2) x (V-b) = RT (Where a = Force of interaction between molecules; b= volume of molecules) ‘Avogadro's Law: Molecular volume = V = MRT/P = (8314.3 x 273.16)/101325 = 22.413 m3lkgmole Equal volume ofall gases at same pressure and temperature contain same number of molecules. (or) Molecular masses ofall the gases occupy same volume at NTP. Clapeyron-Mondeleyer Equation: a mole of gas => PV = 8314.3 T Intensive Properties = Not related to masses (Specific Properties, Temperature, Pressure) Extensive Properties = Related to mass (Volume, Enthaipy, Internal Energy) Kinetic Energy = (4) X Mass X (Velocity)2 ; Potential Energy = M X g X (Elevation); Q -W = U2- Ut Steady flow Energy equation => g Z1 + ut + ptv' + [(C1)2/2] + Q = g Z2 + u2 + p2va + [(C2)2/2] + W Mass flow rate = m = "1X At X Ct = "1X A2 X C2 => (A X C1 Jivt = (A2 X C2 2 Nozzies (Adiabatic) => 9 22 - g Z1 = 0 => ht + [(C1)2/2] = ha + [(C2)2/2 => C2 = > (2 (Rt -h2)+ (C1)2] Throttle Valves => Workless adiabatic expansion => K.E. = P.E. = 0=> ht =h2 1. Properties of Steam Enthalpy of steam = m X [hf + (x Xhfg) + Cp (Tsup ~ Tsat)) \Vsup = [Vg X (Tsup/Tsat)] [where Psup = Psat]; And for wet steam Vw = [(1-x) X (xX Val] Bucket Calorimeter: [ms X {hf —h3 + (x X hfgt)}] = (me ~ mw) X (h3 ~ h2) X Specific heat of water (Where hit, hfg1 and ms for steam, me and mw for Calorimeter: t2 and h2 for water in; 3 and h3 for water out} Separating Calorimeter: x = (Mass of dry steam/Tolal mass of steam) = mi(m+m1) Throttling Calorimeter: ht + (x1 X higt) = hf2 + Cp (Tsup - Tsal) Combined Separating & Throttling: x = (x1 X x2); Where x2 = m/(m+m1) (First separates mass m and then throttles); Moisture-Mass to Throttling = {(1 - x1) X ml Mass to Separator = [(1-x) X (m+mt)]; Removed by Separator = [(1- x2) X (m+mt)] Duplex Feed Pump = Double acting Pump - Two pumps mounted side by side. Brake Power to drive pump = (m X g X H)/(Efficiency) watts, where m is in kg/s, Indian BOE Exam Guide Book (Edition-1) Author : MITHILESH SINGH, mobile: +91-9827482029, Email : mithileshkhudawalagmalPART-A [Syllabus ,Guideline, Formulae& Numerical Exercise] 4 \Volume of water pumped = Area X Length X Number of strokes X Number of Cylinders, 2. Draught At NTP, Volume of 1 mol = 22.4 m3 And molecular mass of air = [(23X32) + (77X28)}/100 = 28.97 kg Density of air at NTP = 28397/22.4 = 1.293 kglm3 ;Amd density of air at Ta°G = [1.293 X (273/Ta)] = 353/Ta Density of Flue Gas at T9°C = [1.298 X (273/Tg)] = 353/T9 Mass of air is 'm’ kg per (1) kg of fuel => Density of Flue gas = “IF = [(m+1}irn] X (953/T9) Draught = Static head = Differential Pressure X Area and h is in mmc => Differential Pressure = p = (“water X (h/1000) X g) in Nim2. = (h X g) in Nim2, So, Draught = [th X 9) X A] = [("la X g X H XA) ~ (FG Xg X HX A] {Where H is the height of Chimney} Draught = h =H X ("1a 1FG )} = H X [(353/Ta) — (953/79) X {(m*1)/m)] Now, Hot gas column (height of gas above chimney top) = Ht. And p = h'X g = IG X 9 XH! FG X g XH! = (hXg) = [HX (a ~ FG )]X g=>H'= [HX ("la—"1FG J} FG HX [(359/Ta) ~ (353/Ta) X ((m¥1)/m}] JA(3B3/T 9) X {(m+1 yim} X f{mitm*1)) X (Ta/Ta) ~ 1) ‘Actual Draught = Ha = (1 ~ loss) XH Velocity of flue gas = V = "1 [2 X 9 X Hal Flue gas Flow through Chimney = Q = KX AX V [Where Condition for maximum discharge through chimney =>T: h'= H metre => h = 176.5 X (HiTg) Loss due to chimney (Due to high exhaust temperature} Heat carried away =(Sp. Heat of Flue gas)X(Temp. of FG in natural draught ~ Temp. of FG in artificial draught ) Heat carried away = Cp X (t~ 12) Maximum energy that a height of hot gas column can give = H X [{m/m+1}} X (Tg/Ta) ~ 1] X g Efficiency of Chimney = (H X {(ru(m#1)} X (TTa) ~ 1} X g¥[Cp X (t= 2)] Heat carried away by Flue Gas = (m+1) X Cp X (t= 12) Heat carried away by Flue Gas as % of Heat supplied = [(m*1) X Cp X (t12)] / (CV per kg of coal) Power required to drive fan = Brake Power = (h X g XV) (Efficiency of Fan) {Where V = Volume handled) Volume of 1 kg of alr at NTP = Vo = 1/(Specific mass) = 1/(1.293) [At temperature To = 273°K] Forced Draught fan => V = [Vo X(Ta/To)X N X mj{Where N = Coal rate (kg/hr); m = air mass (kg/kg of coal)} induced Draught fan => V = [Vo X (TgITo) X NX (m#1)] (BP. -ID)(B.P-FD) = im+tym} X (To/Tal} Velocity head to be imparted to air Hv = (v2\/(2 X 9) Pressure equivalent to Velocity Head = m X g X Hv = ("1X V) X @X Hv = 1.293 X 1 X 9.81 X [(v2\(2X o)} Draught lost = (p/g) in mmwe = (Where pis in Pascal) pV = mRT => Volume of Air = (m X 287 X Ta) (1,013 X 100000) Volume of Fiue Gas = (met) X 287 X Tal / (1.013 X 100000) Inclined leg manometer => aXd=AXh2=AX (h—ht)=AX (h- (dX sin] = coetficiont of velocity = (0.3-0.5)] 2XTaX {(m+1)im} 3. Condenser Corrected Vacuum = 760 ~ (Barometric Height - Vacuum ) mm Absolute Pressure in Condenser = Plot = Barometric Height ~ Vacuum Reading Dalton’s Law: P = Ps + Pa; Gas Law: Pa X V = ma X RXT; ma = ViVa&ms = V/Vs; m = ma + ms = [(1/Va) + (1/Vs)] = ma [1 + (Va/Vs)} = ms [1 + (Vs/Va)] P1 = Ideal pressure corresponding to condensate temperature; P = Actual Pressure = Pot - Pa Vacuum Efficiency = Actual Vacuum/ldeal Vacuum = (Barometric Pr ~ P) / (Barometric Pr- P1) Condenser Efficiency = (Temp rise in cooling water) / (Vacuum related Temp ~ CW Inlet Temp) Coefficient of Performance (COP) (Measure of efficiency of surface Condenser in removing latent heat, only) Cooling Water Outler Temp = Saturation Temperature => COP = (Towo ~ Towi{(Tsat ~ Tcond) + 5] Condenser heat exchange => mw X Cpw X (Two ~ Two) = ms {hf + (x Xhfg)~ N41] I separate pumps for water and air are given and vacuum is same throughout the condenser Indian BOE Exam Guide Book (Edition-1) Author : MITHILESH SINGH, mobile: +91-9827482029, Email : mithlloshkhudawal@gmall.comPART-A [Syllabus ,G e, Formulae& Numerical Exercise] 5 Mass of vapour associated with air [= ms1 At air pump suction Ta1)|[= ms2 At air pump discharge Ta2)} Jet Condenser: Steam & water are mixed =>ms X xXhfg = mw X Cpw X (Two - Two) [hfg =Latent heat at Ps and Two = Tsat] [Vs = Volume of condensed steam/water with Density = 1000 kg/ m3) Capacity of Dry Air Pump = Va = [(ma X R X Ta) / Pa] m3/hr; Capacity of Wet Air Pump = Va + Vs Evaporative Condenser: Heat from steam = ms [hf + (x Xhfg) - ht] {Vs = Sp. Volume of steam at Ps and Va = Sp. Vol by PaV = mRT) [P = Pa + Ps} Mass of vapour associated with 1 kg of air = msi = (Vail Vsi) and mso = (Vao/Vso) Heat given to air = ma X Cpa X (To ~ Ti) and Heat given to vapour = ma X [(mso X Ho) - (msi X Hi)} Water vapour evaporated = ma X [mso - msi ] per kg of dry air 4, Area, Perimeter, Surface Area & Volume Triangle: A = ¥4 X Base X Height; P = a + b + c Rectangle: A = length X width; P = (length + width) Circle: & = ("V/4)X D2); P= 1 XD Annulus: A= (V4) X (D2 - d2) Sector: A = Ye Xr X 8; 8= FX [("/960) X I] Segment: A = ¥4 X r2 (radA ~ sinA) Ellipse: A = T0X (a + by; P= 7X (a + b) X constant Sides of Ellipse big = 2 X a: small= 2 Xb Regular Prisam: V = % XnXr Xa X hi Lateral area =n XAXh-= PXh; P = perimeter of base and a = side Cylinder: V = 01 X 12. XW; $ = (2XOXI2) + (2X0X0Xn) Truncated: h = % X(ht + h2y; V=OX2Xh Hollow Cylinder: V = (1 X h X (R2 - 2) Sphere: V = (4/3)X) X13; $ = 4X1 X 12 Cone: V = (1/3) X 1 X12 Xb S = (FIEIXAXS) + (71 X 2) Cone Frustum: Cube: V = 23; S aise X (12+ rr #72) X a2 Box Ve aXbXc;S=2X (ab +ac+ be) 5. Stross. Hoop Stress: ft = (pdi2t); {as [p X (4 X I] = [ft X (2t X 1] Longitudinal stress ft = (pd/at); (as [p X (5/4) X (d)2] = [ft X 1X d X t} Maximum shear stress = (fmax ~ fmin) / 2 Riveted joints: Original strength = P = fi X p Xt; Tearing Tension = Pt = ft X (p-d) Xt ‘Shearing = Ps = Single = 1 X fs X(7/4) X (42 ; Double riveted = 1.875 (or 2) X fs X(-i/4) X (42 Crushing = Pe = fe Xn X d X ty Efficiency = (Least of Pt, Ps & Pc)/P Actual ioad = Pa = (P)(Factor of safety); Actual stress = {= (Pay/A 6. Fuels HV = [35 X (C/100)] + [143 X ((H ~ 0/8)/100)] + [9.16 X (S/100)] Mulkg [C, H, © & S are in %] Lev = HCV — Hw ‘Oxygen in fuel is believed to be associated with hydrogen only. For 8 part oxygen there is 1 part hydrogen. Enthalpy of steam at 25°C = 2442.5 kuikg of steam = 2.4425 MW/kg of steam > Heat loss in evaporation of H20 formed from hydrogen of fuel = 2.2425 X (9 X H/100) = 2X (H/100) => LCV = [35 X (C/100)] + [121 X {(H ~ 0/8)/100)] + [9.16 X ($/100)] Mulkg [C, H, O & S are in %] There are fixed number of molecules in a Mole. Mass of mole may be different as shown, H= 1 => H2 = 2; 0 =8 => 02 = 16; C= 12; S = 32; N= 14 => N2 = 28; H20 = 18; CO2 = 44; CO = 26. Number of molecules are same in H2 and in H20, but mass is different. One mole of H2 and haif mole of 02 makes one mole of H20. Same way, one mole of C and one mole of ©2 makes one mole of CO2 ‘One mole of substance occupies 22.4 m3 (at NTP) Energy Release (Change in internal energy) Solid/Liquid => Isothermal (V=C) Gas=> Isothermal (P=C) In gaseous preocess volume gets changed => work is to be considered Bomb Calorimeter: M(fuel) X CV = (Mw + Meq-container) X Cpw X (Two — Twi) Gas Calorimeter: (Pn X Vn/Tn = (1.01333 X Vn)/272 and Ts = (273+15)K LCV can be calculated by substracting (Mcondensate X 2442.5) Indian BOE Exam Guide Book (Edition-1) Author : MITHILESH SINGH, mobile: +91-9827482029, Email : mithileshkhudawal@gmail.comPART-A [Syllabus ,Guideline, Formulae& Numerical Exercise] 6 7. Combustion of Fuels Air Composition: By Mass ~ (23% Oxygen, 77% Nitrogen}; By Volume - (21% Oxygen, 79% Nitrogen ‘Theoretical Air required for combustion = (100/23) X ((32/12)C + 8H + SO] Gravimetric Analysis: For hydrocarbons (fuel with Carbon and Hydrogen only) xkg carbon in 1 kg fuel, kg air; (12 kg C in one mole, 2 kg H in one mole, 32 kg O in one mol etc.) => Mos = [(x/12) x C] + [(1-x)!2 X H2] + [(0.23y/92) X 02} + [(0.77y/28) X NZI = a(GO) + b(CO2) + {02} + d{H20) + (0.77/28) X N2] When fuel % is given in volume, division by molecular mass is not required, as % shows mols. (20% = 0.. mol) Flue gas volumetric analysis: To find Air supplied for combustion (Mass of N2 in Fiue Gas) / (Mass of carbon in FG) = [28 X (N% in FG)}/ [12 X (CO% + CO2 % in FG)] => Mass of N2 in Air (or FG) per kg of fuel = ([28 X N%Y [12 X (CO% + CO2 % J} [C% in Fuel/100} And Mass of N2 in Air 77 X Wait = (77/100) X Wair Comparing, Wa = [(Ni% in FG by vol.) X (C% in fuel by mass)} / (38 X (CO% + CO2 % in FG by vol) Now, N2 in excess air by vol ts (79/21) X (02%) and N2 in total air by vol is N2 % ‘And N2 ratio = Air Ralio => (Excess AirTotal Ait) = (79/21) X (O2%)]/IN2 %) Excess Air = [(79/21) X (O2%}]/IN2 %] X {N% X C% ] [33 X (CO% + CO2 % J} When C, N.CO2 & CO are given in mass, then for 1 kg of fuel, Wa = [N% X 0% ]/ [77 X {(12128)CO% + (12/44)CO2 % )} = [N% X 0% ]/ (33XCO%) + (21XCO2 % }] Requirement of oxygen for gaseous fuel: H2 -> % m3 ; CO -> % m3 :C -> 1 m3 ;CH4 -> 2; C2H4 -> 3; C3H6>6 And Air requirement = (100/21) X Oxygen in m3 When Dry Flue Gas Analysis is given (To find Excess air supplied) Quantity of air supplied = V + Vi (Minimum Air = V, Excess Air = V1) Excess Air = (Oxygen % in FG) (21%) = (V1)(V * V1) => V1 = (V = Oxygen %) / (21 ~ Oxygen %) 8. Calculation of heat losses Dry Flue gas per kg of fuel = m X Cp X (T+) [where Cp = 1.004 kukgk] Water formed by combustion of H2 of fuel = 9 X H X 4.1868 X [(100-t) + hfg + {0.48 X (T-100)}] Water (Moisture) in fuel = Mw X [ 4.1868 X (100-t) + hfg + {0.48 X (T-100)}] Incomplete combustion = (C% in fuel) X [(CO%) (CO% + CO2%) by vol] X 24800 kW/kg Hydrocarbon e.g. CH = (CH4% in fuel by vol) X [(CO% + CO2% + CH4% ) by vollX (4/3) X 55700 kJ/kg Unbutnt in Ash: [(C% in Ash X Mass of Ash) / 100] X 35000 kJ/kg in case of IC Engine (By circulating water) = Mew X Ow X (To ~ Ti) Unaccounted losses = Total Heat supplied ~ (Heat utlized + Counted Losses) APH Leakage in % = [(Oown siream 02 — Upstream 02) / (21 - Down stream O2)] X 100 602% + 02% = 19 {coal fired) = 15.5 (Oil fired) ORSAT Apparatus: A = Measuring burette, E = Levelling bottle B absorb CO2 20 times of KOH (Caustic Potash) C absorbs 02 two times of pyrogallic acid (alkaline it absorbs CO2 also. D absorbs CO with Cuprous Chloride (acidic) and Metal Copper (one times) it absorbs 02 also, Nitrogen is obtained by difference. Indian BOE Exam Guide Book (Edition-1) Author : MITHILESH SINGH, mobile: +91-9827482029, Email : mithileshkhudawal@gmail.com& Numerical Exercise] 7 PART-A [Syllabus ,Guideline, Formul A/4.Numerical Excersice Question -1 :In a 200MW unit, coal of 3500 kcal/kg GCV is fired. The ash content in the coal is 40%. If the un-burnt in bottom ash is 3.5% and in fly ash it is 0.5%, Calculate the efficiency loss in Percentage due to un-burnt ( take the ratio of bottom ash to fly ash is 20:80. The GCV of carbon may be taken as 8130kcallkg. Solution : Total ash in coal per kg=1x 40/100 =0.4 kg Quantity of bottom ash per kg coal=0.4x0.2=0.08 kg Quantity of fy ash per kg coal=0.4x0.820.32 kg 0028 kg Un-burnt in bottom ash =0.08 x 0.035= Un-burnt in fly ash=0.32 X 0.005=0.0016 kg ‘Sbefficiency loss due to un-bumt in bottom ash =0.0028 x 8130x100/3500 = 0.6504% 0016 x 8130x100/3500 = 0.3716% ‘heficiency loss due to un-bumt in fly as! Total % efficiency loss due to un-bumnt =0.6504%+0.37 16% = 1.022% Ans. Question -2 :Find out the height of a chimney on bases of following data: Static draught: 30 mmwe, Flue gas temp 230 degC, Ambient temp:30degC. (Air and Flue gas density NTP are 1.293 and 1.34kgim3 respectively) ‘Solution :suppose H is the height of chimney, Density of air at 30 degC= 1,293 x 279/303=1.165kg/m3 Density of flue gas at 230 degO=1.34 x 273/503=0.7273 kgim3 Now , Draught produced by chimney =(H x density of air)(H x density of flue gas) 80 H x (1.165-.7273) H =68.54 meter. Ans. Question -3 :A boiler generates 40,000 kg of steam per hour at a pressure of 17.Sata superheated to a temperature of 295 degC. From water at a temperature of 25 degC. If GCV of fuel is 7400 kcal/kg and boiler efficiency is 76%. Calculate the weight of the fuel burnt per hour. Take Cp of ‘superheated steam as 0.55 UP BOE-2003 Solution :17.Sata=17.6x 1.013=17.7 bar. From steam table, hg=667kcal/kg, ts=206.34 degC Therefore enthalpy of superheated steam per kg ‘hs’=hg*cp\tsup-ts) Indian BOE Exam Guide Book (Edition-1) Author : MITHILESH SINGH, mobile: +91-9827482029, Email : mithileshkhudawalagmall.comPART-A [Syllabus ,Guideline, Formul & Numerical Exercise] 8 = 667+0.55(295-206.34)= 715.763kcallkg Now heat input .000x 715.763 kcal Say, fuel burnt per hour= f kg Now, efficiency of boiler =heat outpul/heat input 0.76 [40,000x(715.763-25)y x 7400 =(40,000x690.763)/(0.76x 7400) = 4912.97kg/hr: Question -4 :One kg of steam at a pressure 14ata and temperature of 294.3 degC is reduced pressure to 3 ata and de-superheated by means of water sprayed at 20 degC and all the water is converted into dry steam. Find out the quantity of water sprayed. The specific heat of superheated steam maybe taken as 0.55. Solution : 14 ata =14.18bar, Hg=686kcallkg, ts=195.6dege. Enthalpy of steam at 14 atahgtcp(tsup-ts) = 686+ 0.55(294.3-195.6)=720.285 kcal/kg Total Enthaipy of slearn=Mass of sleamx enthalpy of SH steam =1X720.285-720,285Kcals At Sata, =133.5degC, hg=650.75kcallkg, Total Enthalpy of dry saturated steam= Mass of steamx enthalpy of dry saturated steam=1x650.75+Mx20 In throttling process total enthalpy will be remain constant 720.288=650.75+20M M=(720.285-660.75)/20 Mass of water spray “M’=3.47675Kg Question -5 :The following is the typical data of APH in a power plant 02 in flue gas inlet -2.8% 02 in flue flue gas outlet-5.7% Flue gas inlet temp-333.5°C Flue gas outlet temp-133.8°C. Air inlet temp-36.1°C. Air outlet temp-288°C Assume mean specific heat of Air and gas as same. Calculate the following Indian BOE Exam Guide Book (Edition-1) Author : MITHILESH SINGH, mobile: +91-9827482029, Email : mithileshkhudawalOgm:PART-A [Syllabus ,Guid ine, Formulae& Numerical Exercise] 9 {a) Leakage of APH in % (b) Flue gas outlet temp at no leakage (c) Gas side efficiency of APH (d) X-ratio of APH CG BOE-2014 Solution : (@) Air heater leakage is determined by an empirical approximation as following AL =(02 gl- 02 ge) x 0.9 x 100 (21-02 gl) Where AL = air heater leakage (%) (O2ge = percent 0 2 in gas entering air heater (2.8 %) (0291 = percent 02 in gas leaving heater (5.7 %) = 5.7 ~2.8* 90/ (21-5.7) = 17.1% (b) The numerical average of the air heater’s gas inlet, gas outlet and air inlet temperatures is calculated. Then the corrected air heater gas outlet temperature is calculated using the following formula, Tonl = AL x Cpax/(Tal - Tae) + Tal 100 x Cpg Where Tan! = gas outlet temperature corrected for no leakage Cpa = the mean specific heat between Tae and Tgl Tae = temperature of air entering air heater (36.1 C) Tal = temp of gas leaving alr heater (133.8 C) Cpg = mean specific heat between Tl and Tgnl Tonl = 17.1 * (133.8 ~ 36.1) + 133.8 = 1504 100 *C (©) The gas side efficiency is defined as the ratio of the temperature drop, corrected for leakag the temperature head, expressed as a percentage. Temperature drop is obtained by subtrat the corrected gas outlet temperature from the gas inlet temperature, Temperature head is obtained by subtracting air inlet temperature from the gas inlet temperature. The corrected gas outlet temperature is defined as the outlet gas temperature calculated for ‘no air heater leakage’ Gas Side Efficiency(GSE) = (Temp drop / Temperature head) * 100 GSE = (Toe Tani) x 100 (Tge ~ Tae) Indian BOE Exam Guide Book (Edition-1) Author : MITHILESH SINGH, mobile: +91-9827482029, Emall : mithileshkhudawal@gmalPART-A [Syllabus ,Guideline, Formulae& Numerical Exercise] 10 Where Tae = Temperature of air entering air heater (36.1 C) Tan = gas out temp corrected for no leakage (150.5 C) GSE = (333.5-150.5) / (833.5-36.1) X100 = 61.5 % X ratio is the ratio of heat capacity of air passing through the air heater to the heat capacity of flue gas passing through the air heater and is calculated using the following formulae = Walt out * Gi Waas in * Cpg = Toas in - Tags out (at no leakage) Tair out - Tair in = (383.5 ~ 150.5) / (288 -36.1) = 0.73 Question -6 : Dui following results 19 an engine trial , the gas as used was tested in a calorimeter and gave the 20 Liter(0.02M') of Gas at pressure 50mmhg above atmospheric pressure of 740mmhg and temperature 18°C was burned, which raised the temperature of 10.2 kg of water from 16°C to 24.5°C and the steam formed was condensed to 209m of water. Calculate the higher & lower calorific values per cubic meter of the gas at a temperature of 0% an pressure of 760mmhg(NTP). Take the heat liberated in condensing the water vapour(steam) an cooling the condensate as 2520KJ/Kg an specific heat of water as 4.187Kj/kg"K. CG BOE-2014 Solution :Higher caloric value H.CN.= —— (Woight of lected in ka x temperature rise in *C Volume of gas burnt in eu M at STP =10.2x(24.5-16)0.02 Hev=4335 Keallkg Lower Calorie value L.C.V = H.C.V.4Ut, of condensate in ka x(Total heat recovered from condensate Volume of gas burnt in m3 at STP =4335-(0,02x(2620/4,187)/0.02}=4335-601 86LCV=3733.14 Keal/kg Question -7 : The percentage composition of a sample of coal on mass basis is as follows Carbon 85%, Hydrogen 12%, Oxygen 3% (a) Determine the minimum air required for complete combustion of 1kg of coal, (b) If Air supplied is 1.Stimes the minimum air required, calculate the mass of dry product of combustion per kg of coal burned. Indian BOE Exam Guide Book (Edition-1) Author : MITHILESH SINGH, mobile: +91-9827482029, Email : mithileshkhudawalOgm:PART-A [Syllabus ,Guideline, Formulae& Numerical Exercise] 11 © The heat carried away by the dry product of combustion leaving the boiler per kg of fuel burned. Given average specific heat of dry flue gas is 1.005 Kj/kg"K and temperature of flue gas is 375°C and boiler house temperature is 25°C. CG BOE-2014 Solution : Given that, Carbon=85%, Hydrogen=12% Oxygen=3% ‘Theoretical air requirement for complete combustion of 1 Kg of coal 100/23x(2.67C+BH+S-0) 100/23x(2,67x0.85+8x0, 12+0-0.03) [35x3,1995 13.92 kg of alr per kg of coal burnt(Answer) While Excess air is 50% ,hence actual alr requirements =1.5x13.92 =20.88 kg of air per kg of coal burnt Total excess air quantity =20.88-13.92 =6.96 kg/kg of coal Total product is of combustion here includes CO2,H20.Excess 02,N2 To find the products of combustion is, (i) Weight of CO2 formed per kg of coal= 3.67xC=3.67X0.85=3.1195Kg (ii) Weight of H20 formed per kg of co: (0.12=1.08Kg (ii) Weight of Excess 02 per kg of coal=0.23x6.9¢ (iv) Weight of N2 per kg of coal= 0,77%20.8 Out of 4 combustion product H20 is not considered in dry product of combustion. Hence Dry flue gas of combustion consist of CO2,Excess 02,N2. ‘Therefore total weight of dry flue gases w= 3.1195+1,6008+16.0776 =20.7979 kg/kg of coal burnt(Answer) Heat loss through dry flue gas =wxCpxAT -20.7979x1,005x(375-25) =7312.88 Kitkg of coal Heat carried away by dry flue gases of combustion heat carried away per kg of moisture in flue gas x weight of H2O formed per kg of coal -2940x1.08 =3175.2 KJ/Kg Total heat loss per kg of coal for heat carried away by flue gases =7312.8843175,2=10,488 KJ/Kg"K (Answer) Question -8 :In a 500MW unit, coal of 4000 kcal/kg GCV Is fired. The un-burnt in bottom ash is 2.8%. and in fly ash is 0.4%. If the ash content in coal is 36%. Calculate the amount of loss due to combustibles in ash in terms kcal/kg coal fired. ( The GCV of carbon may be taken as 8130kcal/kg CG BOE-2014 Total ash in coal per kg=1x 36/100 =0.36 kg, Quantity of bottom ash per kg coal=0.36x0.15=0.054 Kg Indian BOE Exam Guide Book (Edition-1) Author : MITHILESH SINGH, mobile: +91-9827482029, Email : mithlleshkhudawaldgm:PART-A [Syllabus ,Guideline, Formu & Numerical Exercise] 12 Quantity of fly ash per kg coal=0.36x0.85=0.306 kg Un-burnt in bottom ash =0.0 x 0,028= 0.001512 kg 306 X 0.00 Un-burnt in fly as! 001224 kg Therefore, Amount of loss for un-bumnt in bottom ash is= 0.001512 X 8130 =12.29256 kcal/kg coal burnt ‘Amount of loss for un-burnt in bottom ash is= 0.001224 X 8130 =8.95112 koal/kg coal burnt Total heat loss due to combustible in ash =12.29256+9.95112 =22.24368 Keallkg of coal burnt(Ans.) Question -9 :Find out the efficiency and evaporation ratio of a coal fired boiler by direct method with the data given below: Quantity of steam(dry saturated) generated 8 TPH Steam pressure/ temperature 10 kglem*(g)/180"C ‘Quantity of coal consumed 1.8 TPH Feed water temperature astc GCV of coal 3200 Keal/kg Enthalpy of steam at 10kgicm’ pressure 665 Keallkg UP BOE-2014 Soluti Efficiency of boiler by direct method ={(8x1000)x(665-85)}x100/(1.8x1000x3200)=464000000/5760000=80.56% Answer Evaporation ratio= Quantity of steam generated/quantiy of fuel consumption =8/1.8=4.44 Answer Question -10 :A steel rod 25mm in diameter and 2 meter long is subjected to an axial pull of 15kN. Find (a) Intensity of stress (b) The strain © Elongation, Take E=2x10° Nimm* UP BOE-2014 Indian BOE Exam Guide Book (Edition-1) Author : MITHILESH SINGH, mobile: +91-9827482029, Email : mithileshkhudawalagmail.comPART-A [Syllabus ,Guideline, Formulae& Numerical Exercise] 13 Solution Intensity of stress 3 jad/Area=PIA =(15x1000)(11/4x25x25) =15000/490.625 =30.57 Nimm2 (Answer) (2) Strain(e) intensity of stress/Modulas of Elasticity= O/E =30.57/2x10° 0.000153 (No unit) (Answer) © Elongation =(Pxi)/(AxE) =(15000x2000)/( 11/4x25x25x2x10°) =30000000/(490.625x200000) =0.3057mm (Answer) Question -11 :The temperature of a 2 meter long rod is raised from 10°C to 80°C. Find the expansion of the rod. If the expansion of the rod is prevented, find stress developed in the material. Take E=1x10° Nimm*, UP BOE-2014 Solution : Given that, Length of rod L=2met Initial temperature T= orc Final temperature T)=80°C ‘Youngs modulus E=1%10° Nimm? Co-efficient of linear expansion a=0.000012/*C Rise in temperature T= T-T, 0-10=70°C (i) Expansion in rod is given by= axTxt. =0.000012x70x2000 =1.68mm (Answer) (i) Thermal stress 6 = OKTRE , =0.000012x70x1x10" =84 Nimm2 (Answer) Question -12 pert ind the power that can be transmitted by a shaft 60mm diameter at 180rpm. The le shear stress is 85 Nimm’ UP BOE-2014 Indian BOE Exam Guide Book (Edition-1) Author : MITHILESH SINGH, mobile: +91-9827482029, Email : mithileshkhudawalOgmalPART-A [Syllabus ,Guideline, Formulae& Numerical Exercise] 14 Solution :Given that, d=60mm ,N=180rpm ,fs= 85 Nimm? Power is given by.P=2"3.14°N*T/60000 Where T=fs*0.196"d"d'd =85°0.196760°60°60 = 3598560 Nmm Power transmitted by shaft "P"=2"3.14"180"3698560/60000 =67796.8704 wattP=67.797KW (Answer) Question -13 :A process requires 6TPH of dry saturated steam at 7 kgicm’(g). Determine the size of pipe line specific volume of steam at 7 kgicm’(g) is 0.24 m'/kg.(Take velocity of steam as 30misec). UP BOE-2014 Solution: Total volume ofthe steam =Flow rate of steam per second x specific volume of steam =(6x1000/3600)x0.24 =0.399 m3/sec Total volume of the steam =Area of the pipeline x velocty ofthe steam or Area= Volume/velocity Area=0.399/30=0.0133m2 mx?=0.0133 70.0139'm 70,0139/3.14=0.00424 r=Vo.00424 065 meter diameter of the pipe line=; Question -14 :A pump is delivering 50m°/hr of water with a discharge pressure of 3.5kgicm’. The water is drawn from a sump where water level is § meter below the pump centre line. The power drawn by the motor is 9.5KW at 90% motor efficiency. Find out the efficiency of the pump. Indian BOE Exam Guide Book (Edition-1) Author : MITHILESH SINGH, mobile: +91-9827482029, Email : mithileshkhudawalOgmall.comPART-A [Syllabus ,Gui ine, Formulae& Numerical Exercise] 15 UP BOE-2014 Solution Hydraulic power Ph= © (mais) x Total head, hd - hs (m) x 8 (kgim3) x g (m/s2)/ 1000 Where hd ~ discharge head, hs ~ suction head, 6 — density ofthe fluid, ¢~ acceleration due to gravity Ph =(60/9600)x(35-5)x1000x9.81/1000 =4.09KW Efficiency of the pump= Hydraulic power Phi Pump shaft power Ps =4.09/(9.5x0.9) 098.55 7.84%(Answer) Question -15 :Calculate the available NPSH for the system where Atmospheric pressure at installation is =0.9kg/em2 Friction loss is 1.5 mtrs Vapor pressure of liquid is =0.45kg/em2 Specific gravity of liquid=0.8 Pressure inside the tank is 0.5kg/em2 Hieght of the liquid level from pump center line is 0.2 mts UP BOE-2014 Solution : Absolute pressure over liquid=0.9+0.5=1.4 kglem2 Effective available NPSH available of pump= = Absolute pressure over liquid + Height pr of liquid -Vapour pressure-friction loss =1.4+(0.2x0.8/10.8)-0.45-(1.5x0.8/10.8) =1.4+0.0148-0.45-0.1111 =0,8569 kg/em2 (Answer) Indian BOE Exam Guide Book (Edition-1) Author : MITHILESH SINGH, mobile: +91-9827482029, EmaiPART-A [S} bus Guideline, Formulae& Numerical Exercise] 16 Question -16 :The percentage composition of a sample of a liquid fuel by wei and hydrogen-15.2%. Calculate ht is carbon-84.8% (a) The weight of air required for the combustion of 1kg of fuel. (b) The volumetric composition of the product of combustion if 15% excess air is supplied, UP BOE-2014 Solution (2) Weight of air required to burn 1 kg of fuel = 4,35 x {(2.6740,848)*(8x0. 152)}=4.35x(2.26416+1.216}=15.14 Kg/Kg of coal (b) Flue gas Y%ecomposition on mass basis Mass of dry flue gas liberated from 1 kg coal burnt = ( 14EA/100)x theoretical aire 1kg of coal = [(1+15/100)x15.14]+1 =18.411 kgikg of coal Composition of flue gas on the basis of mass. i) COZ by mass = (44/12)x0.848=3.109 Kgikg of fuel % CO2 = 3.109/18.411 = 16.87% (i) 20 by mass = (36/4)x0.152 =1.968 Kg/kg of fuel % H20 = 1.368/18.411= 7.43% (il) 02 by mass=(23/100)x(AAS-TAS) =0.23x(17.411-15, 14)=0.522 Kgikg of fue % 02=0.522/18.411=2.83% (iv) N2 by mass=(77/100)xAAS=0.77x17.411=13.41 Kgikg of fuel %N2=13.41/18.411=72.84% Calculation of flue gas on the basis of Volume Constitue | % Mass of | Atomic Specificvolume [oiEM «| -~—s% Volume) nts FiGia) weight(b) | c=(a/b) | Coz 76.87 aa 038 | 0.38/8.48 10.92% 20 748 8 om 0413.48 11.78% 02 283 [008 0.09/3.48 250% NZ 7284 | 28 26 2.613.48 TATN% | 348 ‘Answer : Product of composition on volume basis ; CO2=10.92%,H20=11.78%,0282.59% & N2=74.71% Indian BOE Exam Guide Book (Edition-1) Author : MITHILESH SINGH, mobile: +91-9827482029, Emai mithileshkhudawal@gmail.come, Formulae& Numeric: PART-A [Syllabus ,Guid Exercise] 17 Question -17: A fan is operating at 900rpm, develops a flow of 3000 Nm3/hr at a static pressure of 600 mmWC, What will be the flow and static pressure if the speed is reduced to 600rpm? UP BOE-2014 Solution :As per fan's affinity law ()_Flowa Speed ie. FyF2=NiJNe 3000/ F=900/600 F,=(8000x600y/900 Flow =2000 Nm3/hr Answer (il) Pressure @ Speed® i.e, Py/P2=(Ny/No)* ‘600/P=(900/600)° P=600x4/9 Static pressure=267 mmWC Answer Question -18 :Calculate the minimum height of chimney required to produce a draft of 19mm of water column if 18kg of air is required per kg of fuel burnt on the grate. The mean temperature of the gas inside the chimney is 357°C and that of atmospheric air 24°C. UP BOE-2014 Solution: Suppose H=Height of chimney to produce a draft Given That, Ta (Ambient temp) is 24°C=297"K T=957*C=630°K , h=19mmWC W=18kg/kg of coal burnt ‘Theoretical draught "n’=353H(1/Ta-{w#1/w)x1/T) 49=353xH(1/297-(19/18}x1/630) 19=353xH(0.0034-1.0556x0.00159) 19=353xH(0.0034-0,00168) 19=353xH(0.00172) 19=Hx0.60716 H=19/0.60716=31.29 meter (Answer) Question -19 :Steam is generated in a boiler at 110 kg/cm2 and 520*c Drum pr. Of the boiler is 118 Kg/cm2 .Calculate-1) Saturated steam temperature 2) Degree of superheat3) Enthalpy of the steam. Solution; 1) From the steam table saturated temperature corresponding to 1 18kg/em2(Orum pressure) is 322%6 2) Degree of super heat is Supetheated steam temperature-salurated temperature=520-322=198%¢ 3) Enthalpy of the superheated steam as found from steam table corresponding to 110kglem2 and 510% Is 815.8kcal/kg Indian BOE Exam Guide Book (Edition-1) Author : MITHILESH SINGH, mobile: +91-9827482029, Email : mithileshkhudawaldgmail.comPART-A [Syllabus ,Guideline, Formulae& Numerical Exercise] 18 Question -20 :in a coal sample it is found total moisture as received basis is 13%. Using suitable formula calculate GCV Of the Direct Coal if GCV of as received coal is 3400 kcal/kg Solution; To obtain GCV value of coal after drying the GCV value as received basis is to be multiplied with 100/(100-TM%) GCV of dry coal=3400(100/100-TM%: 1400(100/100-13) =3908kcal/kg Question -21 :In a Boiler the exhaust flue gas temperature is 145°C and that of ambient air is 35°C Calculate energy loss in dry exhaust gas per kg. if specific heat of flue gas is 0.23kcal/kg. Solution; Energy loss= Mass of flue gas*Cy(Tp.Ta) =1%0.23(145-35)=25. kcal/kg of flue gas. Question -22 :In a200NB Pipe line, steam at 20kg/cm’ and 380°C flows. The velocity measured and found 20m/sec. Calculate steam flow in M'/Hr and Ton/Hr. Sol n;Diameter{D) of the pipe is 200mm= 0.2meter Velocity is given as 20m/sec. Volumetric flow= Area of pipe x Velocity = 110,27/4%20=0,628 m’/sec =2261m/Hr From the steam table specific volume of steam at 20 ka/om? and 380°C = 0.149m*rkg Weight of steam flow per hour=2261/0.149=15174kg/Hr=18.17 ton/Hr Question -23 Velocity of steam in the pipe line is 3 m/sec. Con: alculate pressure drop in a 100 NB, 150meter long horizontal steam pipe line. er friction factor 0.005. Solution; Given that, F iction factor(0.005}, L = Length of pipe 150 meter U = flow velocity m/sec 9 = gravitational constant, 9.81 m/sec’ D = diameter of the pipe 100mm=0.meter Pressure drop(meter) in horizontal pipe line is calculated by =(4fLU?)/(2gD) Pressure drop =(4x0.005x1 50x3x3)(2x9.81x0.1) = 13.78 meter = 1.37 Kg/em* Indian BOE Exam Guide Book (Edition-1) Author : MITHILESH SINGH, mobile: 491-9827482028, Emall: mithlleshkhudawalgmall.comPART-A [Syllabus ,Guideline, Formulae& Numerical Exercise] 19 Question -24 :A 1500 rpm,40 MW, 50HZ,Generator is connected to 8000 RPM steam turbine through ‘speed reducing gear box. Calculate speed of turbine when Generator frequency is 51Hz. =120xfrequency/Nos of poles Nos of pole=120xfrequency/speed=120x50/1500=4piles Ratio of the gear box =8000/1500=5.3333 At 1Hz,speed of generator =120%51/4=1830rpm, So speed of the turbine when generator rpm is 1530rpm =1630x5.3333=8160rpm Question -25 :On line oxygen analyzer of a boiler is showing 4.5%.Calculate the excess air percentage at which the boller is operating. Solution;Excess air% (02%x100)/(21-02%)) 5x100)(21-4.5) =27.27% Question -26 :The safety valve of a boiler is set at 42 Kg/cm2.during testing it is found valve lifts at 45 kglom?2 and reset at 39.5kg/cm2. calculate 1) Over pressure ii) % Blowdown Solution;i) Over pressure = lifting pressure ~ set pressure= 45-42=3 kglem2 Over pressure percentage=Overpressurex100/Sel Pressure=3x100/4257.14% ii) Blowdown percentage={(Set pressure-Reset pressure)x100)/Set Pressure = {(42-39.5)x100)/42 =5.95% ‘Question -27 :Following readings are noted from a power plant cooling tower + Cooling water flow 1500m3/hr * Cooling water inlet temperature 38°C © Cooling water outlet temperature 30%¢ + Wet bulb temperature 27" + Dry bulb temperature 45¢c * TDS of cooling water 1500ppm + TDS of makeup water 250ppm * Evaporation loss 2% + Windage loss negligible Calculate; i) Approach iil) Range ) Heat load of the cooling tower Indian BOE Exam Guide Book (Edition-1) Author : MITHILESH SINGH, mobile: +91-9827482029, Email : mithileshkhudawalogmall.comPART-A [Syllabus ,Guideline, Formulae& Numerical Exercise] 20 iy) coc v) Blowdown vi) Makeup water required Solution; (i) Approad (i) Range = Inlet hot water temperature-Oullet let cold water temperature (ii) Heat Load=Flow rate(kg)*Specific heatx(inlet temp.- Outlet Temp.) =1500*1000%1(38-30)=12000000kcal/hr Out let Cold water temperature-wet bulb temperature= 30-275 3'¢ 8-30 (iv) COC=TDS of cooling water/TDS of makeup water '500/250=6 (v) %Blow dows % Evaporation/(COC-1)2/(6-1 MN Mehr Jow rate x Sbblow dowr '500x0.4%=1500x0.00: Blow down quantity: (vi) Make up water required '500x0.02+6 =3046 ‘vaporation losses + Blow dow: =36 M'fhour Question -28 :200 TPH steam is generated in a boiler at 100 kg/cm® Pressure and 500% temp. feed water inlet temp. is 135% and 52 ton of coal is consumed per hour than calculate, 1. Equivalent evaporation from and at 100° 2. Equivalent evaporation from and at 100°c per ton of coal 3. Boiler HP. Solution; 1. Equivalent evaporation in the quality of water evaporated from and at 100% to produce dry saturated steam at 100% by absorbing the same amount of heat equal to actual operating condition, (Latent heat of dry saturated steam at 100°C is 539 kcalkg) Heat in steam at 100 kg /em? pressure , 500°c temperature is 809 kcal/kg, Meq=(Mao(H- Hs)W/535 (200(809-135))/539=250TPH 2.To find equivalent evaporation from and at 100°c per ton of coal M,qis taken as actual steam generation per unit quantity of fuel Mg in this case = 100/82 = 3.85 tons of steam per ton of coal So Mgq~(3.85(809-135)}/539=4.81TPH 3. One Boiler HP is the capacity to evaporate 15.653 kg of feed water per hour at 100° ¢ into dry saturated steam at 100° c. Boller HP = equivalent evaporation from and at 100 ° ¢ (kg/hr)/15.653 =250x1000/15.653 =15971HP- Indian BOE Exam Guide Book (Edition-1) Author : MITHILESH SINGH, mobile: +91-9827482029, EmailPART-A [Syllabus ,Guideline, Formulae& Numerical Exercise] 21 Question -29 :For a STPH capacity furnace oil fired , estimate the rise to temperature of water in a economizer which brings down the flue gas temperature from 280°C to 180°C. Air to fuel ratio and Evaporation ratio of the boiler are 20 & 10 respectively. Assume condensate recovery is Nil & Specific heat of the flue gas is 0.23Kcal/kg*C. Solution : Evaporation Ratio (Or Mass of fuel consumption =Mass of steam generation/Mass of fuel consumption lass of steam generation/Evaporation ratio 1000/10=500Kg/hr tass of fuel consumption + Mass of air consumption 10+20x500=10,500 kg/hr lass of FIG x Specitic heat x(temperature difference) 500x0.23x(280-180) 41,500 Keals leat transfer/Mass of feed water fw 41,500/5000 =48.3°C Mass of flue gas generation Total heat transfer Rise of feed water temp Question -30 :The efficiency of a boiler on GCV basis is 85%. The fuel contains 1% moisture and 12% hydrogen. The GCV of fuel is 10,000Kcal/kg. What is the boiler efficiency on the basis of NCV(Net calorific value). Solution NCV =GOV{94H+M)x584] 10,000-{84(0.12+0.01)x584) 9,316.73 Keallkg Efficiency of boiler on NCV basis _—_—=Erfciency of boiler GCV basis x(GCVINCV) =0.85x(10,000/9,316.73)=0.9123 =91.23% Question -31 : The following observation were taken during a test on a steam boiler : ‘Quantity of coal burnt per hour 750kg Food water supplied per hour 7000kg Calorific value of coal fired 8100kcal/kg ‘Temperature of feed water entering into economizer, 20°C ‘Temperature of feed water leaving from economizer Bore Steam pressure 10Kgflem2. Dryness fraction of steam leaving boller drum 0.97 ‘Temperature of steam leaving super heater 250°C Determine the thermal efficiency of the plant also calculate the heat absorbed by feed water in various components as a % of the total heat absorbed, From steam table at 10kgflem2 ts=179.04°C _hf=181.2kcallkg hfg=482kcallkg at 10kgflem?2 & 250°C MP BOE-2000 Solution : Thermal efficiency of the boiler =heat outpul/heat input =Mi(hsup-hf)(AxGCV) 7000x(702.4-20)(750x8100) =4776800/6075000=0.7863=78.63% Heat absorbed by feed water in various camponents 1. In Economizer =MxsxAt=7000xt x(80-20)=420000 Keals ‘% heat absorption in economizer=420000/4776B00=0.0879=8.79% 2. InEvaporator =Mx(hsat-hig)=7000x((181.2+0.97x482.1]-80) 100x(648.837-80)=7000x568.837=3981859 Kcals ‘% heat absorption in evaporator=3981859/4776800=0,8336=83.36% 3._ In Super heater =Mx(hsup-hsat)=7000x(702,4-648.837)=7000x53.563"374941 Keals % heat absorption in super heater=374941/4776800=0.07849=7,849% Indian BOE Exam Guide Book (Edition-1) Author : MITHILESH SINGH, mobile: +91-9827482029, Email : mithileshkhudawaldgmall.comPART-A [Syllabus ,Guideline, Formulae& Numerical Exer fe] 22 Question -32 : Water is supplied to the boiler at 15 bar and 80°C and steam 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. Solution : From steam table Entropy at boller inlet water=1.075kikg*k Heat supplied to the steam is passing through the boiler= =Enthalpy at boiler outlet-Enthalpy at bolle inlet Ho ={hfexchfg)-hi (8.44,0/4,18}+0.9x1(2789.914.18)-(844.6/4.18)}-80 [202.06+0.9x(687.44-202,06)}-80 -620.902-80=540.902 Kcallkg"C =2260.97 Kj/kg*C_ Entropy at boiler oullet's’ Sex Sig °2.314+0.9x(6.441-2.314) 6.0283 Ki/kg*K 0283-1.075 34.933 Kj/Kg*K Change in Entropy Question -33 :A coal having C V 3500kcall/kg. Is supplied to power station . The boiler , Turbine , and Generator efficiency are 83%, 32%, 97% respectively . If the coal consumption of the power station is 30T/hr. Determine the capacity of power plant in MW. ((W"Cvy"qb" nt ngy[860"1000] Coal consumption by boiler per hour in kg Calorie value in Keal/kg nb = Efficiency of Boiler at =Efficiency of Turbine ng Efficiency of generator Solution :Capacity of Power Plant(MW Where As per above equation, =[ (20"1000°3500)*0.83°0.32"0.97)/1860"1000]=31.46MW Question -34 :In a condenser test the following observations were made : Vacuum 70 cm of hg Barometer 76 cm of hg Mean temperature of condensate 340°c Hot well temperature 290% Mass of cooling water 102000 kg per hour Inlet temperature 170° Outlet temperature 310% Mass of condensate 2620 per hour. Find {a) The mass of air present per m3 of condenser volume (b) The state of steam entering condenser {c) The vacuum efficiency Solution :Given that, Condenser vacuum=70emhg=700mmhg Barometric pressure=76cmhg=760mmhg Mean condensate temperature=34"C. Condensate temperature=29"C. Rise in temperature of cooling water=31-17=14°C Rate of steam condensation=2620 Kgihr Rate of cooling water flow=102000 Kg/hr Indian BOE Exam Guide Book (Edition-1) Author : MITHILESH SINGH, mobile: +91-9827482029, Email : mithileshkhudawalagmail.comPART-A [Syllabus ,Guideline, Formulae& Numerical Exercise] 23 Absolute pressure in condenser =Barometer pressure-Condenser vacuum =760-700=60mmhg =60x0.001359 ( 1kgf/cm2=0.001359mmhg) =0.08154Kgt/em2 (a) Mass of air present per m3 of condenser volume. Partial pressure of air in the condenser =Absolute pr in condenser-Partial pr of steam at 34°C (08154-0,05423=0.02731 Kaflem2 Partial pressure of steam is known from steam table at 34°C absolute pressur =0.05423Kgficm2 Applying the characteristics gas equation PV=mRT miV =(PIRT) = (0.02731X104 J(29.27X(273+34)) =273/8985.89= 0.03038 Kg/M3 (b) State of steam entering condenser(Dryness fraction of steam) Steam at 34°C Sensible heat=34Kcal/kg & Latent heat L=613.3 Keallkg (from steam table) From as per heat balance equation Exhaust steam & condensate water side Ms(hw+x.L-heond) = Cooling water side (MxCpxAt) 2620(34+x.613,3-29) =102000.1.14 X=0,8805 © The Vacuum Efficiency= Condenser Vacuum / Ideal Vacuum ‘00. X100)/[760-(0.05423/0.001359)] =97.21% .05318bar Question -35 :A 60 MW turbine operating at 40% Load factor is fed from a boiler with 85% iency. Burning coal of CV of 27900 Kj/kg. The Turbine steam consumption without feed heating system is 4725Kg/kwh. The boiler feed temp is first case Is 31%c and in tho later case Is 93°C. Calculate the coal saving per year if turbine is running with feed heating system. Spec heat capacity of water is 4.19Kj/kg"C MP BOE-1992 &1996 Solution : ‘Total power generation in a year = 60x1000x365x24x0.40 =210240000Kwh/annum Total steam consumption without fees heating system = 210240000x4725 = 993384000000 kg of steam/annum ‘Saving of heat loss in a year due to the charging of feed heating system = MxCpxat +=993384000000x4.19x(93-31) =2.5806x10"“kjannum Mass of Coal saving in a year = Heat saving per annum/(GCV of coal x Efficiency of Boiler) =[(2.5808x10"*) /(27900x0.85)] =1.088172043x10"" Kg, of coal =1,08,81,720.43 MT of coal per annum Question -36 :Calculate daily fuel saving of fuel oil by providing an Economizer for a boiler having performance data as given below: ‘Steam generated - 5 T/H Flue gas temperature ~ 315*c ( without economizer ) Steam generated/Kg of fuel oil - 14 Kg Feed water inlet temperature - 110° Fuel oil supply rate - 314 kgih Flue gas quantity - 17.4 kg/kg of fuel GCV of fuel - 10000 kcal/kg @ in feed water temperature by providing economizer ~ 26*c Neglect CBD Solution :Heat gain by economizer in to the boiler after installation of economizer =5x1000x1x26 =130000 Kcal per hour Energy saving equivalent amount fuel oll =130000/10000 Indian BOE Exam Guide Book (Edition-1) Author : MITHILESH SINGH, mobile: +91-9827482029, Email : mithileshkhudawalagmail.com '3 kg/hr =312 kg of fuel oil/dayPART-A [Syllabus ,Guideline, Formulae& Numerical Exercise] 24 Question -37 : For a coal containing 5% hydrogen ( GCV = 5600 kcal/kg ) , estimate the percentage of sensible and latent heat loss due to evaporation of water formed due to hydrogen in the fuel, if the flue gas temperature is 180c and combustion air temperature is 40c. (latent heat of vapors= 584 KcallKg , specific heat of vapours = 0.45 Kcal/Kgic) Solution : Percentage Heat loss due to hydrogen present in fuel -OxH2x(584+CpxAt)x100/GCV of fuel =9x0.05x(584+0.45x140)x1 00/5500 =5.20% Question -38 :Assume the stochiometric air to fuel ratio of furnace oil is 14. The burner operates at 20% excess air . Calculate the mass of stack gas generated from combustion of one kg of oil. Solution : For stochiomettic air requirement for furnace oll combustion ‘kg of furnace oil required 14 kg of air Including to excess air total air requirement =14x1.20 =16.8 kg of air Alter the combustion mass of flue gas generation 16.8 kg of air+1 kg of furnace oil =17.8 kg of flue gas Question -39 :Calculate the quantity of cooling water required in Kg/minute for a surface condenser to condense 18 kg per steam per minute . The dryness fraction of steam is 0.9 and the temperature of steam entering the condenser is 37c. The inlet and outlet temperature of cooling water are 28"c &18*c respectively. The condensate temperature is 37c. The latent heat of steam. should be taken as 576 kcal/kg. Solution ‘Suppose “mis the quantity of cooling water required for surface condenser. As per heat &mass balance ‘Turbine exhaust heat=Heat discharged to condenser 48x576x0,9=mx1x(28-18) m=18x576x0.9/10 Quantity of cooling water required for surface condenser =933.12kgiminute Question -40 :A boiler generates 40 ton of steam per hour at a pressure of 17.5 ata superheated to a 295c from economizer water at temperature of 25c . If cv of fuel is 7400 Kcallkg and boiler efficiency is 76%. Calculate the weight of fuel burnt per hour. Take Cp of superheated steam as 0.55. Solution: Given that Calorific value of fule=7400Kcal/kg Efficiency of boiler=76% ‘Steam generation=40x1000kg Specific heat of super heatedstaer ‘Superheated temp at Boller outlet=205°C Feed water temp at economizer tem=25°C (Output heat of Boller = 40X1000x0.55x(295-25) =5940000 Kcal Weight of fuel burnt per hour =Output heat of boileri(Erficiency CV of fuel) +=5940000/(0.76x7400) =1056.19 Kg per hour =1.05619 MT per hour Indian BOE Exam Guide Book (Edition-1) Author : MITHILESH SINGH, mobile: +91-9827482028, Email : mithileshkhudawalOgmail.comPART-A [Syllabus Guideline, Formulae& Numerical Exercise] 25 ‘Question -41 : A forced draught fan discharge 1200 cubic meter of air per minute through the outlet of 2.1 square meter and maintains a static prossure of 10 cm of water . The temperature of air is 27c . Calculate the BHP of the motor to drive the forced draught fan if the efficiency of fan is 80%. Assume the weight of 1 cubic meter of air at NTP is 1.293 Kg Solution : Here Discharge volume of air V=1200m3/min Pressure P=100mmwc=100kg/m2 Efficiency of the fan= 80% BHP of motor= PW/4500xn =100x1200/4500x0.8 =33.33 Question -42 ‘The vacuum at the air extraction pipe in a condenser is 71 ms of mercury ( barometer 76 cm ) and the temperature is 36c . The air lekage In to condenser is 5kg per 10000 kg of steam, Determine a- Volume of air to be dealt with the dry air pump per kg of steam entering the condenser b- Weight of water vapour associated with the alr. Solution : 76cm=760mm & 71em=710mm Pabs=Pair-Psat Pabs=760-710=50mm Hg=50x0.001359 Kgficm2=0,06795kgt/em2 Partial pressure of air 06795-Psat at 36*c (06795-0.06000 00795kgt/cm2 Volume of air in the condenser PV=mRT 0.00795xV=5x29.27x(273+36) 1\V=5688320.755m3 Volume of air to be dealt with the dry air pump per kg of steam entering the condenser= +=5688320,755/10000 =5688.32 m3 (Answer) Weight of water vapour associated with air= =5/5688,32 0.00088 kgm3(Answer) Question -43 :A chimney is 28 mtr high and the temperature of hot gases inside the chimney is. 320 c and the furnace is supplied with 15 kg of air per kg of coal burnt. Calculate a: Theoretical draught in mm of water b- Draught head in meters of hot gasaes - The velocity of flue gases in the chimney if 60% of draught is lost in friction of grate and passages. Solution ‘Supposed Ta (Ambient temp) is 25°C=298"K Given as H=28meters =320°C=593°K w=15kgikg of coal burnt ‘Theoretical draught h=953H(1/Ta-wst/wx1/T) mmWe h=353x26(1/298-16/15x1/593) h=353x28x0,001857 5.39 mm of water h=0.01539 meters of wator(Answer) Indian BOE Exam Guide Book (Edition-1) Author : MITHILESH SINGH, mobile: +91-9827482029, Email : mithileshkhudawaldgmall.comlabus ,Guideline, Formulae& Numerical Exercise] 26 ‘Available draught is 40% of the theoretical draught available draught. P=0.4X15,39=6,156 mmwc=6. 156X9.81Nim2 Now this pressure is caused by height of gas column Hg Higx353(we" vox Tx9.81=6.158X8.81 (Or Hgx359(15+)/15x593=6.156 (Or Hgx0.635=6.156, Or Hg=9.694m Velocity of flue gas in chimney= \V=N(2xgxHg) =\2x9.81x9.694=13,79 m/sec (Answer) Question : 44. - A surface condenser condenses 20 tons per hour of exhaust steam at 49 degree from a turbo - alternator. The dryness fraction of the steam is 0.85. Determine the flow rate of cooling water if cooling water inlet temperature is 33 degree c , cooling water outlet temperature is 42 degree c. Solution : Latent heat exhausted by turbine=Heat exchange to cooling water Exhaust steam flow X Enthalpy of steam X dryness factor=QX( Outlet ~inlet temp) (Cooling water flow)=20x(SH steam enthalpy from steam table at 49°C)X0.85/ (42-33) =20TPHX(670.4Kcal/kg)X0.85/9°C =1077.4TPH Question : 45 - Calculate the blow down rate for a boiler with an evaporation rate of § Ton / hr, if the maximum permissible TDS in boiler water is 3500 ppm & with 17% make up water addition The feed water TDS is around 350 ppm. Solution % Blow down = =TDS of feed water X%DM water makeup /(Max permissible TDS limit of Boiler water) =(350X17)X/3500= 5950/3500=1.7% Blow down rate = Blowdown %ageX(Evaporation rate of Boiler) =0.017X5=0.085TPH Question : 46 - Coal with 35% ash is fired in a boiler . Coal consumption is 80 tons on a specific Day. Clinker is formed by 2% of the ash sticking to boiler tubes. How many Tons of ash are going out of the boiler on same day . Solution :Total ash generated by boiler in a specific day= =80X0.36 =28tons Total ash going out of the boiler on same day= =Total ash generated by boller in a specific dayX(100-slicking ash into boller tubes)/100 =28X(100-2)/100 =27.Aétons per day Question : 47 - Steam at a pressure of 15 kg/cm2(g) if flashed to a lower pressure of 2kglem2(g) . If the steam flow rate is 1000 kg/hr . Calculate the % of flash steam & flow rate of flash steam Solution St: Hf Sensible heat at higher pressure al 15kg/em2(g) Le. 16Kg/em2(abs) 858. Ski/kg=205.28Kcal/kg S2:hf, Sensible heat at lower pressure at 2kgicm2(g) i.e. 3kg/em(abs) 561, Skj/kg=134.27Kcal/kg L2infg, Latent heat at lower pressure at 2kglcm2(g) ie. 3kgicm2(abs) =2163.2Ki/kg=517.26Kcal/kg, % Flash stear=($1-S2)X100/L2 =(208.28-134.2)X100/517,26 =13,74% Flow rate of flash steam= flash steam X Steam flow rate =0.1374X1 000kgihr=137.4Kg/hr Indian BOE Exam Guide Book (Edition-1) Author : MITHILESH SINGH, mobile: +91-9827482029, Email : mithileshkhudawal@gmalic: PART-A [Syllabus ,Guideline, Formulae& Num Exercise] 27 Question : 48 - Find the number & diameter of 3000mm long tubes required in a fire tube boiler to got total surface area 20 m2 & total cross section area of 0.07 m2 for the flue gas, Solution : Total cross section area of flue gas 0.07m2=7.R2 Radius of flue gas zone 15m Diameter =2xR 2x0.15=0.3m) Diameter to one tube=0.30m Total surface area of one tub =2X3.14X0.18X3=2.826m2 Total number of tubes=Total surface area/Total surface area of one tube =20/2.826=7 Total number of tubes=7 (0.071) ARh Question :49 - It is proposed to replace an oil-fired boiler of 10 tons per hour with a coal fired boiler of equivalent capacity . With the help of the data provided find out the following. a the annual oil consumption in tons per hour b- the annual coal consumption in tons per hou ¢- estimate annual fuel cost saving in crore rupees d - simplepay back period of the project, assuming the coal fired boiler costs Rs 1.5 crore and annual repair and maintenance costs of the coal fired boiler are 25% of capital cost . Operational data is : heat content of steam 760 kcal/kg Feed water inlet tempr 70 degree c Daily operating hours 24 Number of days / hour 280 Efficiency of oil fired boiler 80% Efficiency of coal fired 74% Cost of oil Rs - 14/kg Cost of coal Rs - 1.4/kg GCV of oil 10,000 kcal/kg GCV of coal 44,00 kcal/kg Solution : Total enthalpy of steam=10X1000X(760-70) 100000 Keals per hour =46368000000 Kcals per annum (a) Annual oil consumption per annum = =0,8625 tons por hr (b) Annual coat consumption per annum= =(46368000000/0.74)/4,400=14240786.24 kg per annum =2119.16kh/hr =2.11916 tons per hr (c) Total cost of oil per annum=5796000X14=Rs.8,11,44,000=8.1144 corers, Total cost of coal per annum=14240786.24X1.4=Rs. 1,99,37,101=1.9937crores, Annual fuel cost saving=8.1144-1.9937 +=6.1207 corers Indian BOE Exam Guide Book (Edition-1) Author : MITHILESH SINGH, mobile: +91-9827482029, Email : mithileshkhudawaldgm:PART-A [Syllabus ,Guideline, Formulae& Numerical Exercise] 28 (@) Total cost of coal fired boiler installation=Project cost + Maintenance cost =1.5+0.375=1.875 corers ‘Simple pay backperiod(Year)= Total cost of boiler installation/Annual fuel saving cost 1 ,87516,1207 tion :50.The following readings were obtained during a boiler trial of 6 hours duration Main steam pressure : 14Kg/cm2(g) Weight of steam generated : 24000kg Mean dryness fraction : 0.9 Mean feed water temperature : 28°C Weight of coal used : 4800Kg Calorific value of coal : 5500Kcal/kg Calculate (i) Factor of equivalent evaporation jon from & at 100" Solution Mact=Actual mass of steam generated per unit mass of fuel burnt=24000/4800=5 H=Total specific enthelpy of steam under operating condition Keall/kg =Total specific Enthalpy of steam at 15Kg/cm2(abs)(below mention value obtained from steam table whereas (1Kcals=4.182K)) =hftchg =201.96+0.9X485.16 =620.604 Keallkg Hwt= Specific enthalpy of feed water Keal/kg at 28°c=28kcal/kg Specific enthalpy of feed water Keal/kg at 100°c=100kcal/kg (i) Factor of equivalent evaporation= F =(H-Hwt)/539=(620.604-28)/539=774.4/539=1.099 (i) Equivalent evaporation at 28%c Feed temiperature= Meq(at 28°C) =MactXF =5X1,09985.495 Equivalent evaporation at 100*c Feed temperatur =5X(620.604-100)/539 =4.83 (ii) Efficiency of Boiler= MX(Hs-HfOXGCV =24000X(620,604-28)/4800X5500 =53.87% Note: This is a very worst case of any boiler Boiler efficiency will be usually in the range of 70% to 85% lets your calculation found in out of this range, please check your calculation once again. legiat 100°C) =MactxF Question :51. In a boiler trial of 24 hours duration, 1600 Kg of coal were consumed to evaporate 12,800 Kg of water. The Main steam pressure was 7.Sbar. The coal contained 3% moisture and 3.9% ash on mass basis. The feed water temperature was 35°C. CV of coal is 30300Kj/kg. The steam produced is dry saturated with enthalpy of 2766.4Kj/Kg. Determine (a) Thermal Efficiency of the Boiler {b) The equivalent evaporation from and at 100°C per kg of dry coal, and {c) The equivalent evaporation from and at 100°C per kg of combustible. CG BOE-2012 Solution (@) Efficiency of Bolter= =MX(Hs-HIOXGCV =12800X(66 1.5-35)/1600X7245.34 =8019200/11592544 Indian BOE Exam Guide Book (Edition-1) Author : MITHILESH SINGH, mobile: +91-9827482029, Email : mithileshkhudawal@gm:PART-A [Syllabus ,G ine, Formulae& Numerical Exercise] 29 69.18% n dry coal basis=128001(1600X0.97)=8,25 combustible basis=12800/(1600X0.921)=8.69 ‘otal specific enthalpy of steam under operating condition 766.4 KJ/kg=661.5Kcal/Kg Hwt= Specific enthalpy of feed water Keal/kg at 35° Factor of equivalent evaporation= F =(H-Hwt)/539=(661 5-35)/539=626,5/539=1,16 (b) Equivalent evaporation from and at 100°C per kg of dry coal =MactXF =8,25X1.16=9.87 (©) Equivalent evaporation from and at 100°C per kg of combustible =MactXF =8,69X1.16=10.08 Mact =36kcalkg Question :52. The following is the %age composition of coal on mass basis : €=90%, H2=3.3%, 02=3%, S=0.9% and remaining ash Calculate (a) The theoretical air required to burn 1Kg of coal completely. (b) The %age composition of dry flue gases on mass basis if 50% excess air is supplied. Assume air has 23% oxygen on mass basis. CG BOE-2012 Solution : a) Theoretical air qty required to burn 1 kg of coal = 4.35 x{{(2.67x0.9)+(8x0.033)+0,009}-0.03) 510.47 Kg/Kg of coal b) Flue gas composition % on mass basis - Mass of dry flue gas liberated from 1 kg coal burnt = ( 1+EA/100)x theoretical airt 1kg of coal =[(1#50/100)x10.47}+1 =16.708 kgikg of coal 1) +02 = CO2, Weight of CO? formed for thg af coal= (44/12)x0.923.303 Kg % cod = 3.303/16.705 = 19.77% 2) 2H2#02=2H20, Weight of H20 formed fort kg of coal = (36/4)x0.099 =0.297 Kg % H20 = 0.297/16.705= 1.78% 3) $+02=S02, Weight of $02 formed for 1 kg of coal = (64/32)x0.009= 0.018 Kg %S02 = 0.018/16.705=0.12% 4) Mass of NO2=0.77XAR=0.77X1.X10.47=12.09Kg ‘%NO2=12.09/16,705=72,37% Indian BOE Exam Guide Book (Edition-1) Author : MITHILESH SINGH, mobile: +91-9827482029, Email : mithileshkhudawalagmail.comPART-A [Syllabus ,Guideline, Formul 30 & Numerical Exerci Question :53 Estimate $02 emission through chimney in Tons/annum. Data as follow: Days considered : 340 Fuel used : Furnace oil Specific gravity : 0.94 Sulphur content : 3.8% Quantity of FO consumption : 3.5KLIhr ‘And If measured 02 in flue gas is 2.5%, Find % Excess air level. MH BOE-2013 Solution : Quantity of sulpher Kg/Annum = 3600%0.94x24x340%0.038 = 1020163.2 Kg/Annum ‘1 Kg of Suphur consumption = 2 Kg of So? generate Hence $02 emission through chimney = 2x1020163.2 = 2040326.4 Kg! Annum. = 2040.32 Tons! Annum % Excess alr = 02% | (21-02%) Question :54 During an study, the inlet gas stream to a bag filter was 150000 m3/hr. The outlet stream from the bag filter was a little bit higher at 160000 m3/hr . Dust load at the inlet was 7gm/m3 and at the outlet 0.2gm/m3. How much dust in Kg/hr was collected in the bag filter bin. MH BOE-2013 Solution : Ratio of inlet and outlet gas volume =160000/150000 = 1.087 Net dust load at outlet = 1.087 x 0.2 gmim3 = 0.213 gmim3 Actual dust collection per m3 volume of gas = 7- 0.213 = 6.787 gmim3 Dust collected in bag filter bin is = 6.787 x 150000 = 1018080 gm/hr = 1018.050 Kg/hr ‘Question :55 - A Circular Shaft Of 60mm diameter is running at 150 rpm. If the shoar stress is not to exceed 50 MPa, find the Power which can be transmitted by the shaft. CG BOE-2013 Solution : to find::: power=2? solution: Indian BOE Exam Guide Book (Edition-1) Author : MITHILESH SINGH, mobile: +91-9627482028, Email : mthileshkhudawalOgmail.com31 PART-A [Syllabus ,Guideline, Formulae& Nume! power is given by.P=2"3.14*N'T/60000 Where T=fs"0.196%d*d'd 50°0.196"60*60"60 =2119500Nmm so power if finally, P=2°3.14*150°2119500/60000 P=33276.15Watt ‘Question :56- A Gas of certain mass is expanded from an initial state of 400KPa and 0.04m: to another condition of 120KPa and 0.1m*. The temperature fall was observed to be 146°C. If the values of Cp and Cv are 1.0216 kJ/kgK respectively, calculate the change in the internal energy of the gas. CG BOE-2013 Solution : change in internal energy is given by...U2-U1=MCv(T2-T1) We know that ptvi=mrtt therefore, m=ptvi/RTt =400°0.04*10"6/286*419, (R=UNIVERSAL GAS CONSTANT,..Temp converted into kelvin)) m=1.3kg, now, pivi/Tt=p2v2/T2 400°0.04/419 =120°0.1/T2 T2=316K ‘Therefore,, Change in internal energy =Mev(T2-T1) '3°1.0216(419-316) 39.44KJ u2ut Question :57- If a shaft has a diameter of 50 mm & the maximum shearing stress is 425 kg/em*. What will be the moment of resistance of shaft to twist. MH BOE-11/2/2012 Solution given:; d=50mm fe=425kg/om*2 to find:::: Moment of resistanceof shaft, solution: Moment of resistance of solid shaft is given by MR=0.1962"fs*d*d"a 1962°425°5*5*5 }0425.78KG.M"2 Mi MR= Question :58- A single riveted lap joint is made in 12mm thickness plates with 22mm diameter rivets. Determine the strength of the rivets, if the pitch of rivet is 60mm. Given allowable stresses in Shearing is 60 MPa, in bearing as 150Mpa, and in tearing as 80 MPa respectively. CG BOE-2013 Solution : Given>>> Indian BOE Exam Guide Book (Edition-1) Author: MITHILESH SINGH, mobile: +91-9827482029, Email : mithileshkhudawalagmail.comPART-A [Syllabus ,Guideline, Formulae& Numerical Exercise] 32 fs=60mpa ft=80mpa to find:: Strength of the rivet?? Solution: resistance against tearing=I =(60-22)"12"80 att =36480N Now, Resistance against shearing=Rs=n*0.785"d"d"ts *0.785*22"22"60 =22796N Thus, strength of rivet is minimum of RI&Rs. Therefore Rivets can sustain the load of 22796N Question :59- Find the work sssure in a fire tube boiler 2.5m in diameter is 2.5mm. Assume that longitudinal stress is not to exceed 10kgflem2. The tube thickness. Solution : Given that 60cm t=2.5mm Bp. 10kgttem2 We know that circumferential stress is double the longitudinal stress, 6,-p*di2*t=circumferential stress_& 3». p*d/4*t=longitudinal stress working pressure p=32-4"tid=10°4"2.5/250=0.4kglem2 Question :60- Find out the thickness of Cl pipe to carry 30m3/min of compressed air at a pressure of Tkglcm2. The velocity of air in the pipe is limited to 8 meters per second. Assume tensile stross i the pipe material to be 150kg/cm2. 6=28,21cm }Om3/min=30/60=0,5m3/min \y=Bmiseo Discharge volume V=(r1/4)"d*velocity oP =Vi(mT/4ay*velocity 0.6/(3.14/4)°8=0,0796mters 2821meters=28.21em Circumferential tensile stress 180=7"28,21/2"t 6582cm Indian BOE Exam Guide Book (Edition-1) Author : MITHILESH SINGH, mobile: +91-9827482029, Emall : mithlleshkhudawal@gmall.comPART-A [Syllabus ,Guideline, Formulae& Numerical Exercise] 33 failable without economizer and fuel oil saving by nas below. Question -61 : Calculate quantity of heat Providing an economizer for a boiler. The performance data of the boiler are g Average quantity of steam generated 5 Thr Average flue gas temperature 315*C (without economizer) Average steam generation/kg of fuel oil 14kg Ambient temperature arc Fuel oll supply quantity 314kg/hr Flue gas quantity 17.4 kgikg of fuel Specific heat of fuel 0.23 keallkg"C. GCV of fuel oi 10000Kcal/kg Rise in feed water temperature by providing economizer 26 Annual operation hours 8600hrs, MH BOE-2013 Solution : Total flue gas quantity =17.4x314=5463.6 Kg/hr Quantity of heat available without economizer }63.6X0.23X(315-40)=345572.7Keal/hr ‘otal flue gas quantity X specific heat X AT Sensible heat gain after installation of economizer= Mass of steam flow X Rise in FW temperature =5X1000X26=130000 Keal/hr Saving of fuel oil= Sensible heat gain after installation of economizer/GCV of fuel oll =130000/10000=13 Kg/hr=13X8600 Kg/annum=111.8 toneslannum 4, 62. Calculate the coal consumption in below mention boiler where S/H temp=440°C, Economizer temp=170"C,GCV of co: generation=45TPH & steam pressure=58kg/cm2. 200Kcal/kg, Steam Solution= ‘Suppose Boller efficiency is 80% Total enthalpy of steam= ‘Steam flow in kgX(Specific enthaply of superheated steam-specific enthalpy of Economizer inlet temp) =45TPHX1000(3276.94Kj/kg/4.18-170) (Kindly note that for sensible heat 1"C=1 Kcal/Kg,) =45000X613.9 =27628062.2 Kcals Total equivalent heat input in the boiler =27628062.2/0.8 =34535077.75 Kcals Coal consumption=Total equivalent heat input in the boller/GCV of coal =34535077.75/4200 =8222.84Kg =8.22264TPH 80 Indian BOE Exam Guide Book (Edition-1) Author : MITHILESH SINGH, mobile: +91-9827482029, Email : mithileshkhudawal@gmail.comPART-A [Syllabus ,Guideline, Formulae& Numerical Exercise] 34 Question -63 :A sample of coal with C=0.78,H2=0.08,02=0.02,N2=0.02 and ash = 0.05 is burnt in a furnace with 50% excess air. The flue gas enter the chimney at 325%c and atmospheric temperature is 15*c . Take the Cp for CO2 , SO2 and air = 1.008 KJ/Kg K. Assume that the heat carried away por kg of moisture in flue gases is 2940 KJ. Calculate the quantity of heat carried away by the flue gases in KJ/Kg k Solution : Given that Carbon=78% Hydrogen=5% Oxygen=2% ,Sulpher=0% & Ash=5% Theoretical air requirement for complete combustion of 1 Kg of coal =100/23x(2.67C+8H*S-0) 4100/23x(2.67x0.78+8x0.05+0-0.02) 4. 35x2.4626 =10.71 kg of air per kg of coal burnt While Excess air is 50% hence actual air requirements =1.6x10.71 16.065 kg of air per kg of coal burnt Excess air quantity =16,065-10.71 5.355 kgikg of coal Total product is of combustion here includes CO2,H20,Excess 02,N2 To find the products of combustion is, (i) Weight of CO2 formed per kg of coal= 3.67xC=3.67X0.78+ (il) Weight of H20 formed per kg of coal=9XH=9x0.05=0.45Kg (ii) Weight of Excess 02 per kg of coal=0.23x5.355=1.23165Kg (iv) Weight of N2 per kg of coal= 0.77x16.085=12.37005Kg .8626KQ (Out of 4 combustion product H20 Is not considered in dry product of combustion, Hence Dry fiue gas af combustion consist of CO2,Excess 02,N2 Therefore total weight of dry flue gases we 2.8626+1.23165+12.37005 = 16.4643 kg/kg of coal burnt Heat loss through dry flue gas ‘wxCpxAT 16.4643x1.008x(325-15) =5144,76 Kulkg of coal Heal carried away by dry flue gases of combustion =heat carried away per kg of moisture in flue gas x weight of H2O formed per kg of coal =2940x0.45 =1323 KJIKg Total heat loss per kg of coal for heat carried away by flue gases =5144,76+1323 =6467.76 KJ/Kg"K (Answer) Question -64 : A boiler drum of total weight 23500kg is supported by four ropes. Find the diameter of ropes if allowable stress for role material is 800 Kglem2. MH BOE-2013 Solution :Given that, W=23500Kg, N24 & Stress (d) =800 kg/om2 Weight carried by an single rope is. W(individual)= W/N=23500/4=5875kg. Thus, diameter oft rope is given by Stress (d)=Weight/Area=5875/(/4"d*) (Rope is considered to be circular) 800=5875/(3.14/4" d’) Diameter of an rope is found to be “d"=3.05em Indian BOE Exam Guide Book (Edition-1) Author : MITHILESH SINGH, mobile: +91-9827482029, Email : mithileshkhudawal@gmail.comPART-A [Syllabus ,Guideline, Formulae& Numerical Exercise] 35 Quostion -65 :A safety valve is designed to blow off at a gauge pressure of 0.8N/mm2. The valve is held by a close coiled helical spring of mean coil diameter 180mm and valve disc diameter is ‘80mm. Find the diameter of spring rod if shear stress of rod is 75Nimm2. ‘AP BOE-2013 Solution : Force=PressureXarea 8x(r0/4)x(80x80) =4019.2 Nr ‘Now according to shear stress consideration on closed coll Helical Spring Shear stress=(16xWxR)/(TIxd") 75=(16x4019.2x90)/(3.14x0°) (0°)=(16x4019,2)(3.14x75) (24574.7)"° Diameter of spring rod=30mm. ‘Question -66 : A hollow shaft is to transmit 300KW at 80RPM. If shear stress is not to exceed 60N/mm2 and internal diameter is 0.6 of the external diameter find the external and internal diameter assuming the max. torque Is 1.4 times the mean torque. ‘AP BOE-2013 Solution : P=300KW=300000W N=80rpm Maximum shear stress ([)= 60N/mm? Internal Diameter Di=0.6xExternal diameter Di=0.6xD0 Max Torque Tmax =1.4 times mean torque =1.4xT Power P= 271NTI60 T=(60xP)/(2PJN)=(60x300x10°)/(2x3.14x80)=35809.7NM_ ‘Tmax=1.4T=1.4x35809.7Nm=50133, 7Nm=50133700Nmm Maximum torque transmitted by hollow shaft is given by equation Tmaxe []/16x x(t? =(8.14/16)x60x((D0"%0. .6D0}*VDo}, 50133700=(3,14/16)x60x0.8704D: (16x50133700)(3,14x60x0.8704)}"° ;ppx. 170mm 6x170=102mm External diameter=170mm & Internal diameter=102mm Question -67 : A boiler is operating at 100bar and 535°C with steam flow rate is 105TPH, the ‘superheater temperature maintained by 2 stage attemperation. Attemperation feed water supplied at 156°C and super heated steam temperature of second stage to be maintained at 490*C to maintain the main steam temperature. The first stage attemperator inlet steam temperature is 515°C. Find the attemperation water flow in the first stage attemperation to maintain the outlet at 490*C[Inlet steam enthalpy, spray water enthalpy and outlet steam enthalpy are 3413.63KJ/KG,658.12KJ/KG and 3349.18KJ/Kg respectively]. ‘AP BOE-2013 Solution : ‘Suppose S is the attemperation water flow in TPH, Inlet steam enthalpy =3413.63KJ/Kg=816.27kcalikg Spray water enthalpy =658. 12KJ/Kg =187 37kcallkg Outlet steam enthalpy =3349. 18KJiKg=800.86kcallkg Inlet heat +Spray heat=Outlet heat (Or (F-S)X816.27+Sx157.37=(F)x800.86 Indian BOE Exam Guide Book (Edition-1) Author : MITHILESH SINGH, mobile: +91-9827482029, Emall : mithileshkhudawal@gmail.comPART-A [Syllabus ,Guideline, Formulae& Numerical Exercise] 36 (Or (105000-S)x816.27+Sx157.37=105000x800.86 (Or 85708950-816,27S+157.378=84090300 (Or 85708350-84090300=816.275-187.378 Or 1618050=658 9S. 18050/658.9=2456.68kg per hour .45568T PH jer working on 100kgicm2, 535°C. Steam flow is 95 TPH.The economizer inlet water temperature is 210°C. Find the coal flow in Tonnes per hour when boiler efficiency is 87% and fuel GCV is 3200 Keal/kg[Steam enthalpy and water enthalpy are 3464.33KJ/Kg and 897.631Kj/Kg respectively). ‘AP BOE.2013 Solution : Coal fiow in tonnes per hour =Mass of steam flowx(Enthalpy of steam-Enthalpy of water)/(Etficiency x GCV of coal) -95X1000x(828.39-214.64)(0.87x3200) =58306250/2784 =20943.2369 Kg per hour=20,9433369 TPH Question -69 : Calculate the weight of coal in tones which is stored in a conical shape in the yard if the diameter at base and height are 100 mts and 75 mts respectively. Assume density of coal is. 0.9kg/M3. ‘AP BOE-2013 Solution : Volume of conical shape: \V=base area * perpendicular height’3 =(nr2)xhi3 =(3.14X60X50)X75/3 =196250mS Weight of coal =Volume of conical shape X density of coal =196250X0.9 =176625kg =176.625 tonnes. Question -70 :In an APH, Gas inlet is 31kg/s with 3.5%oxygen in the outlet the oxygen content increases to 4.2%. Find the leakage quantity of air and also find the increases in ID fan load % due to the leakage. AP BOE-2013 Solution : %Excess air=02X100/(21-02) Excess air content at 3.5% O2=3.6x100/(21-3.5) Excess air content at 4.2% O2=4.2x100/(21-4.2) % Increment of excess air=25-20=5% Leakage quantity=% Increment of excess air X Gas inlet flow=0.05x31= 1.55kg/s Increase in 1D fan loading%=Leakage quantityx7100/Gas inlet flow =1,55X100/31=5% Question -71 :Find the rise in temperature of air in a pre-heater if 16 kg of air is supplied per kg of fuel burnt & temperature of flue gases drops in pre-heater is 139 c . The efficiency of pre-heater is. 78% the specific heat of flue gases and air is 0.24 Solution :Heat transfer of flue gas to Air =Flue gas mass on 1 Kg of fuel supplied (1 fuel+16 alr) x Specific heat x temperature difference of flue {gas across Air pre-heater= (1+16)x0.24x130= 567.12 Kcals on supplied 1 Kg of fuel Effective heat transfer from flue gas to Air= Heal transfer of flue gas to Al x Efficiency of air pre-heater 567.12 x0,78=442,3536 Kcal on supplied 1 Kg of fuel fective heat transfer from flue gas to Alirl(1+Ratio of air & fuel) +=26.0208*C Indian BOE Exam Guide Book (Edition-1) Author : MITHILESH SINGH, mobile: +91-9827482029, Email : mithlleshkhudawal@gm:PART-A [Syllabus ,Gi ine, Formulae& Numerical Exercise] 37 Question -72 : Estimate the condenser cooling water flow rates for a 400MW power plant if the water under goes 10°C temp rise. Assume plant overall efficiency as 40% and boiler efficiency as. 80%, Cpw=4.187 MP BOE-2014 Solution : Turbine efficiency=Overall efficiency/Boiler efficiency 0.4/,8=0.50=50% 400MWHper hr=400000Kwh/hr=400000X3600Ki/hr=1440000000Ki/hr Total latent heat discharge by cooling tower=1440000000/Turbine efficiency=1440000000/0,5=2880000000K;thr H=m X Cpw X delta T Cooling water flow m=Hi(Cpw X delta T}=1440000000/(4.187x10)=34392166.23Kg/hr =34392.16623 Tonnes/hr Question -73 :During a trial of a condenser following readings were taken : Barometer reading - 766 mm of mercury Actual vacuum in condenser -710mm of mercury Temp of hot well - 29 deg c Inlet temp.of cooling water - 18 deg c Outlet temp.of cooling water - 27 deg c Determine : 1- Vacuum corrected to a saturated barome! 2+ Vacuum efficiency 3 - Under cooling of condensate 4 Coefficient of performance r of 760 mm of mercury Solution :Absolute vacuum=766-710=56mm of Hg Corrected vacuum=760-58=704mm of Hg Vacuum efficiency \ctual vacuum/Ideal vacuum) '66-56)/(766-30.43)=7 10/735.57=0.9652=96.52% Under cooling of condensate=39-29=10"C {30°C equivalent saturation temp of 56mm of h(0.70 bar)} Coefficient of performance i.e. condenser efficiency 2-1 (ts-t1)=(27-18)(29-18)=9/1 1=0.8181=81.81% Question -74 :The vacuum in the condenser shell is 710 mm of Hg and atmospheric pressure is 760 mm of Hg. The temp.at inlet and outlet of the air cooling section are 35 deg c and 30 deg Calculate for a leakage of 0.50 kg of air per hour . 1- The volume of air entering the cooling section per hour and 2+ The mass of steam condensed per hour in the section ,Take R of alr as 0.294 KJ/Kg K Solution :Total absolute pressure in condenser 10-710=50 mm of hg=50/750=0.0667bar {1bar=750 mm of hg} ‘At 35°C Partial pressure of vapour=0.05622bar {from steam table} Partial pressure of air=0.0667-0.05622=0.01048bar Pa.VirT1=P2.V2/T2 Orv2 =(P1.VisT1pT2IP2 0.7734x1.0133/273}x{(35+273)/0.01048] _{1kg of alr occupies 0.734 m3 at NTP(O%e) =0.00287x29389.31=84,35 m3 ‘Therefore volume of air entering the cooling section per hour =0.5X84,35=42.175 m3 ‘Steam at pattial pressure of 0.05622 bar and 35°C will occupy the same volume i.e. 42.175 m3 Mass of steam steam entering the cooling section per hour =42,175/2.5245=18.7kg { Specificvol of dry saturated steam al 35°C=2.5245m3/kg) Indian BOE Exam Guide Book (Edition-1) Author : MITHILESH SINGH, mobile: +91-9827482029, Email : mithileshkhudawal@gmall.comPART-A [Syllabus ,Guideline, Formulae& Numerical Exercise] 38 ‘At 30 °C Partial pressure of vapour=0.04246bar {from steam table} Partial pressure of vapour=0.0867-0.04246=0.02424 bar Volume of air at 30°C and 0.02424 bar pressure 0.5x{(0.7734x1.0133)/273}x{(30*273)0.02424) 0.5x0,0287x12500=179.375 m3 volume of vapour Mass of vapour in air=179.375/30.929=5.8kg Mass of steam condensed/hr in the cooling section =16.7-5.8=10.9kg Question -75 :A surface condenser operate at a vacuum of 699.2 mm of Hg , when the barometric head is 760 mm of Hg. It receives steam at the rate of 10 tons per hour, which is 0.9 dry , calculate 1-condenser efficiency 2 ~ cooling water flow rate If cooling water inlet tem. = 33 deg ¢ and outlet temp. = 40 deg c Solution :Absolute pressure in condenser=(760-699.2)/760 =0.08bar absolute pressure AtO.08bar absolute pressure corresponding saturation temperature is 41.53°C Condenser efficiency= (12-t1)/(ts-t1) =(40-33)/(64.53-33) =7/8.53=0.8208=82.06% Mw={msx(ht+xhfg)-heY{Cpwx(t2-t1)] =[10000x0.9X2403,2)[4,186x(40-23)] {here value of hf=hc} -21628800/29302 =738 tonnes/hr Question -76 :In a surface condensing plant the following data were obtained ‘Temp of exhaust steam entering the condenser = 42.67 dege . ‘Temp of condensate leaving the condenser = 35 degc , Inlet temp of cooling water 6.5 dege & outlet temp = 30 deg c Quantity of cooling water per hour 46250 kgs , Quantity of condensate per hour 1190 Kos Calculate the dryness fraction of Exhaust steam entering the condenser Solution :Suppose X is the dryness fraction of exhaust steam entering the condenser Heat gained by cooling water=Heat lost by steam (Or MwxCpwx(t2-t1 }=Msx(hf+X. hfg-he) (Or 46250x4, 186x(30-16,5)=1 190x( 178.694+X.2578.28-146.37) Or 1190(2578.28X+32.324)=2611136.25 (Or 2578.28X+32.324=2611136.25/1190 Or 2578.28X+32.324=2194.29214 (Or 2578.28X=2194.23214-32.324=2161.91 Indian BOE Exam Guide Book (Edition-1) Author : MITHILESH SINGH, mobile: +91-9827482029, Email : mithileshkhudawaldgmall.comPART-A [Syllabus ,Guideline, Formulae& Numerical Exercise] 39 (Or X=2161.91/2678.28= Dryness fraction of exhaust steam =0.84 Question -77 :A surface condenser deals with 2100 kgs steam and the air leakage amounts to 0.8 kglhr. The temp.of the air pump suction is 350C & the vacuum is 580 mm of Hg when barometer reads 760 m of Hg. Determine the capacity of the wet air pump which has a volumetric efficiency of 75%. Solution: Absolute pressure in Condenser = (760 ~ 580/750 = 0.24 bar ‘At 360 C, the partial pressure of vapour = 0.05628 bar Hence partial pressure of air = 0.24 ~ 0.05628 = 0.184 bar Volume of air at this condition 8 x {(0.7734 x 1.0133) / 273} x {(35 + 273) / 0.184) {844 m3 per hour Volume of condensate = 2100 x 0.00101 = 2.121 m3 Wet air to be handled by the pump = 3.844 + 2,121= 5.965 m3 per hour Volumetric capacity of the pump required = 5.965) 0.75 = 7.953 m3/ hour Question -78 :In a small capacity of Thermal Power plant, the condenser is provided with a ‘separate air-cooling section. The temp.of steam entering the condenser is 560C and temp. at the air pump section is 460C. The barometer reads 76 cm of Hg, find (1) Vacuum in Condenser (2) If discharge of dry air-pump is 90 m3/min., find the air leakage the condenser in kg/hr. Solution: Considering no ingress of air at the inlet, the pressure in the condenser will be the same as the pressure of the steam entering at that temperature. From the steam table at 56°C, the corresponding pressure 1653 bar absolute = 0.1653 x 750 = 123.98 mm of Hg, Vacuum in the condenser = 760 ~ 123.98 = 636.02 mm of Hg Now at the outlet the partial pressure of the steam = 0.10101 bar abs. (from steam table at 46*C) ‘Therefore the partial pressure of air = 0.1653 ~ 0.10101 = 0.0643 bar ‘The discharge of air pump = 90 m3/ min = 840m3/ hr. Here T = 46°C + 273 = 319 K,P = 0.0643 bar = 0.0643 x 102 kPa, V = 540 m3, R of alr= 0.287 kil kg K PV = mT. ‘Therefore mass of air leakage in the condenser per hour me (0.0643 x 102 x 540)/ (0.287 x 319) = 37.93 kg/hr ‘Question -79 : A surface condenser condenses steam at the rate of 20t/hr which leaves the condenser at the corresponding saturation temp. The condenser operates at a vacuum of 680mm of hg. Determine (a) Condenser efficiency (b) Flow rate of cooling water (c) Number of condenser tubes Where CW inlet temp=33%c,CW outlet temp=43°c, Mean velocity of cooling water =2.5m/s, ID of condenser tubes=19.6mm,Barometer pressure=760mm of hg & steam is 0.95 dry Solution: Absolute pressure=Barometer pressure-vacuum in the condenser =760-680=80mm of hg=80/70=0.10867bar At 0.10667bar corresponding saturation temp will be 46.96°C Condenser efficiency= t2-t1 (st )=(43-33)/(46,96-33)=10/13.9% 571.63% Heat gained by cooling water=Heat lost by steam Or MwxCpwx(t2-t1)=Msx(ht*X.hfg-he) 7163 Indian BOE Exam Guide Book (Edition-1) Author : MITHILESH SINGH, mobile: +91-9627482029, Email : mithileshkhudawalggmall.comPART-A [Syllabus ,Guideline, Formulae& Numerical Exercise] 40 Flow rate of cooling water Mw=(Msx(hf#X.hfg-he)}/(Cpwx(t2-t1)) :20000x(199,7+0.95x2388, 4-199. 7}/(4.182x(43-33)} '20000x2268.98)/41.82=10851 17.169 kg/hr=301.42kg/se0=301.42/1000 mS/se .30142m3/sec Area of one tube A=(3.14x(0.0196x0.0196)}/4=0.0003 m2 Volume of one tune=Area of one tube X velocity of cooling wat Nos. of lubes= Flow rate of cooling water/Flow rate of one tubs (0003x2.5 =0.00075m3/ 0.30142/0.00075=401.85 02 tubes Question -80 : The vacuum produced in a surface condenser is 685mm of hg when the barometer reading Is 760mm of hg. The condensing steam temp is 36°C. The net volume of steam space Is 25m3. Determine (a) The partial pressure of air (b) The mass of air present in the condenser, Solution: Absolute pressure =760-685=75mm of hg=75/750=0. tbar Partial pressure of air= Absolute pressure-Saturation pressure =0. 1 0bar-0.0594bar=0.0408bar=0,04192kaflcm2 PvemRT Mass of sir present in the condenser m =PVIRT (0.04192x10000x25)/(29.27x(273+36)) =10480/9044,43 =1.16kg Question-81: A close circular tank is to be installed in a boiler house as a feed water tank. Diameter and height of tank are 2.1m and 6m respectively. Find water holding capacity of the tank. Also find the cost for insulating the tank including top with insulation thickness of 50mm. Assume insulation cost Rs. 145/m2. Solution : Volume of the circular tank =m. 3.14x1.05 41.05% 7711m (Holding capacity of tank) “Tank vertical face area+ Tank top face area. mek + me ‘14x1.10x6.05)+(3.14xt.10x1.10) =20.8967+3.7994 =24.6961m? s. 3581/- Tank insulation area Insulation Cost=24.6961x145 Question-82: Find the volume of 1 Kg of steam at a pressure of 14kg/cm2(g), in each of the following case:~ (i) When steam is dry saturated. When steam is wet having a dryness fraction of 0.9. When steam is superheated, the degree of superheat being 40°C. Solution : (From steam table (Table No.-2, Saturated pressure table) Volume of dry saturated steam at 15kg/cem2(abs) A3167m3/kg (i) Volume of wet steam at 15kg/em2(abs) v=x.vg=0.9x0.13167=0.118503m3/kg (ii) From steam table (Table No.~8, Specific volume of superheated steam) Saturation temperature at 1Skgicm2{abs) is 198.3°C. Degree of superneat is 40°C Temperature of the superheated steam=198.3+40=298,9°C Volume of superheated steam at 15kglcm2(abs) & 238.3°C =0.147492 m3/kg Indian BOE Exam Guide Book (Edition-1) : MITHILESH SINGH, mobile: +91-9827482029, Email : mithileshkhudawalgmall.comPART-A [Syllabus ,Guideline, Formulae& Numerical Exercise] 41 Question-83: The following data was obtaining during a test on two boilers working under similar conditions, except that the draught in the first boiler was produced by an induced draught fan and in the second fan by a forced draught fan:~ Air suppliedikg of fue! burnt 19kg Density of air under given conditions: 4.205kgim3 Density of flue gases at the specific temp 0.769kgim3 ‘Combustion rato 150kg of fuel/hr Fan draught produced in each case 75mmwe Efficiency of fan in both cases 50% Calculate Brake Horsepower of fan in each case. Solution : BHP = Q x SP / (6356 x Fan Eff.) Where , + BHP = Break Horsepower + Q = Air flow rate in CFM + SP = Static pressure in-WG Calculation of BHP in 1™ Case (ID Fan) Calculation of BHP in 2” Case (FD Fan) Flow rate of flue gas ‘Q’ Flow rate of air =150x20=3000kg/hr=50kgimin=50x0.769m3/min | =150x1! -38.45m3/min=38.45x35,31CFM m/min: =1367.67CFM =2021.056CFM '7_Skgimin=47.5x1.205 1=57.2375x36.31CFM Brake horsepower(BHP) of ID fa Brake horsepower(BHP) of FD fan= 1357.67x75/(6356x0.50) =2021.056x75/(6356x0.50) 1825.25/3178=32.04HP =151579,2/3178=47.69HP Question-84; During the test of an oll fired water tube boiler, the following data was obtained:- Steam pressure 48kgicm2(ab) Weight of water evaporated 283kg/min Boiler feed water temp 76°C Quality of steam 99% Weight of fuel burnt 22.45kgimin Calculate ~ {a) Actual evaporation per kg of fuel oll (b) Factor of equivalent evaporation (c) Equivalent evaporation from and at 100°C (d) Boiler horsepower Solution : (2) Evaporation rate ‘Mact’=283/22.45=12.61 kg of steam/kg of fuel oil (b) Specific enthalpy of steam under the operating condition Keal/kg 'H’ =Total enthalpy of steam at 16kg/cm2(abs) [from steam table] =866.15 Keallkg Factor of equivalent evaporation 'F” _=(H-Hwt)/539=(866. 15-76)/539=1.47 © Equivalent evaporation from and at 100°C. =MactxF 2.61 x[(866.15-100)/539] 2.61x1.421=17.92 (d) Meq =Mactx[(H-Hfw)/539) =(283x60/1000)x|(866.15-76)/539} =16.98x1,47=24.9606TPH One Boiler HP is the capacity to evaporate 15.659 kg of feed water per hour at 100°C into dry saturated steam at 100°C. Boiler HP = Meq/15.653=24.9606/15.653=1.595HP Indian BOE Exam Guide Book (Edition-1) Author : MITHILESH SINGH, mobile: +91-9827482029, Email : mithileshkhudawaldgm:PART-A [Syllabus ,Guidel ine, Formulae& Numerical Exercise] 42 Question-85: Convert (i) 122.5x10" Keal to (li) Delta 280°C to... 19.97m3Isec to.. MTOE. Delta *F. CFM, mm of water column, (v) Evaporation of 976kg of waterihr to... “Boller HP Solution : (i) 122,5x10°Keal—-=122.5x10°/10,000 TOE, 122.8x10° TOE 122.x10°/10" MTOE =12.25 MTOE (i) Delta 280°C =Delta 536°F. (ii) 19.97m3/sec =19,97/60 m3/min 0,3328 m3/min 0.9328x35.31CFM 11.75CFM, (iv)167mmHg =164.80mmWc Here, 760mmHg=750mmWC (v) Evaporation of 976kg of waterhr__=0.976 TPH/15.853 Boiler HP =0.062 Boiler HP Question-86: Estimate the pipe size required to carry dry saturated steam at 65 kg/cm’(g) pressure from boiler giving steam flow 68750 kg/hr. Assume steam velocity 38m/sec. Solution : Steam pressure =65kgicm2(q)=66kg/cm2(abs) Specific volume of 66kg/cm2(abs)___=0.029218 m'/kg Steam flow at 66kgiom2(abs _)=68750kg/hr=19,097kg/sec Volume of steam team flow x specific volume =19.097x0.029218=0.56m3/sec ‘olume of steamivelocity of steam 56(38=0.0147m2 Steam pipe Area rear 0.0147=3.14xr? (1°) =0.0147/3.14=0.047 Radius of pipe ‘r'=V0.047=0.217meter Diameter of pipes XF=2x0.217=0.434meter=434mm, Question-87: Following observations are noted during coal fired boiler trial: Ultimate analysis of coal 1: H2-2%, 02-5%, C-38%,S-1%, moisture-5%. 02 in flue gas 3% Flue gas temperature at boiler exist : 140°C Ambient air temperature 240°C GCV of coal 13400 keal/kg Specific heat of flue gas 23 keallkg"C Specific heat of superheated steam :0.45 kcal/kg*C Calculate (a) % Heat loss due to dry flue gas (b) %Heat loss due to evaporation of water formed due to hydrogen in fuel. (c) %Heat loss due to evaporation of moisture present in combustion air. Indian BOE Exam Guide Book (Edition-1) Author : MITHILESH SINGH, mobile: +91-9827482029, Email : mithileshkhudawal@gmall.comPART-A [Syllabus ,Guideline, Formul & Numerical Exercise] 43 Solution Theoretical air requirement for coal = 100/23x(2.67C+8H+S-0) 4. 95x(2.67x0.38+8x0,02+0.01-0.05) =4.35x(1.0146+0.16+0.01-0.05) =4.35x.1346=4,93551 kg of aitlkg of coal Excess air =[0,x100V/[21-02] ={3x100}/[21-3]=300/18=16.67% Actual air requirement =4.93551x1.1667=5.758 kg of air/kg of coal Flue gas generation =145,758=6.758 kg of flue gasikg of coal (a) Heat loss due to dry flue gas. =[mxCpx(TI-Ta)x100VGCV of fuel =[6.758x0.23x(140-40)x100)3400 4.57 % (b) %Heat loss due to evaporation of water formed due to hydrogen in fucl= =[9xH2x{584+Cp(TF-Ta)}x100]/GCV of fuel [(9x0.02x(584+0.45x(140-40))x100)/3400 +=[9x0.02x{584+45}x100]/3400=3,33% © %Heat loss due to evaporation of moisture present in combustion air= [Mx(584+Cp(TI-Ta))x100)GCV of fuel {0.05x{584+0.45x(140-40))x100/3400 {0.05x629x100}/3400=0.925 % Question-88: A 5000 kg/hr boiler operates at 10.5kg/cm2(g) and has a maximum allowable boiler ‘TDS of 3500ppm. Calculate blow down rate in kg/hr. If the boiler is operated with manual blow down and assuming that boiler water TDS is maintained at 2500ppm. Assume boiler feed water ‘TDS is 300ppm and feed water temperature is 30°C. Calculate energy loss due to excess blow down, Solution : % Blowdown _=[TDS of FWx100)[Max permissible TDS-TDS of FW] ‘% Blow down at Max permissible limit(3500ppm)=[300x' 0O}[3600-300] =30000/3200=9.375% Blow down rate at Max permissible limit=5000x9.375%=468.75 kg/hr % Blow down at manual operated(2500ppm) = [300x100)/[2500-300} =30000/2200=13.64% Blow down rate at manual operated=8000x13.64%=682.00 kgihr Loss of water due to manual blow down= 682-468.75=213.25 kglhr Energy loss due to excess blow down due to manual operation =213.25x30 =6397.5 kCal/hr Question-89: Calculate the total heat of 1kg of steam at a pressure of 9kg/em2(g) when :- (i) Steam is wet having dryness fraction is 0.85. im is dry saturated. is ted at 205°C. Considering specific heat of superheated steam(Cp) is 0.55. Solution From steam table of [Table No.2] Saturated pressure table ‘Steam at the pressure 9kg/em2(g) or 10kgicma(abs) hf =762.6 kjkg & hg=2776.2 kjkg Saturated steam temp 'ts'= 179.9°C (a) Total enthalpy of wet steam === hf#x.hg =762,6+0,85x2776,2=3122.37kikg 5747 keallkg (©) Total enthalpy of dry saturated steam —=nf+thg 162.6+2776.2 =3538.8kikg 46.2 keallkg © Total heat of superheated steam = hf+hg+Cp(Tsup-Tsal) Indian BOE Exam Guide Book (Edition-1) Author ! MITHILESH SINGH, mobile: +91-9827482029, Email : mithileshkhudawaldgmail.comlabus ,Guideline, Formulae& Numerical Exercise] 44 =182.35+663.85+0.55(205-179.9) =860 Keallkg Question-90 ; Determine the difference in pressure between two points 1Km apart in 150mm bor horizontal pipe work system, The water flows at rate 45m3/hr at 15*C and friction factor for pipe is 0.005. Solution : O=Axv Asrr f= 3.14x75x75=17662.5 M2 V=Qi/A=(45x3600)/17862.5=9.17m!s Head loss due to friction HP =[4flv’/(Dx2g) [4x0.005x9.171000x9,17x9.17/[150x2x9.81] 15421.9043/2943=5.24m Difference in pressure drop ‘AP’ =p.g.Hf 4x9,81x5,24=51.4044meter 8.14044 Kglem2 Indian BOE Exam Guide Book (Edition-1) Author : MITHILESH SINGH, mobile: +91-9827482029, Email : mithileshkhudawal@gmall.comPART-B[Boiler Engineering(Paper-1&2)] 1 B/1.Precaution to be taken while inspecting any Boiler To avoid the accident while inspecting the boiler/boiler parts , All officers after their appointments are given guidelines about precautions to be taken while inspecting the boiler. All officers should take following precautions for their safety. + Helmet is very much essential while entering the factory premises, without helmet do not enter in factory. If own helmet is not available then ask for helmet with management for time being, ‘+ Before climbing the boiler (Oil fired boiler) for boiler inspection be sure that, oil is not spilled around the boiler. + Above fact will not come to notice if sufficient light is not there. So carry the inspe sufficient light is available ‘There is a scaffolding provided for inspection of large boilers for climbing on boiler. First confirm the strength & rigidity of scaffolding. Generally the ply of scaffolding should be 8 to 9", by which boiler at every level can inspected thoroughly, + It ls compulsory to the boiler owners to provide sufficient security under The Boilers Act, 1923 - Section 14(1) FOR INSPECTION OF BOILER. Inspector can refuse the boiler Inspection under Section 14(2), ihe feels that scaffolding or staircase is not strong enough for climbing on boiler and submit report to the Director, n only when ‘+ There is a chance of getting injury to knee on hitting Drum internals while getting down in Steam, Drum. Therefore first carefully understand about welded parts of drum & then enter in drum for inspection. Take proper care of eyes & head, While getting down in Steam drum/water drum first open the manhole and see the internal portion of drum. There is possibility of dogs, snakes or honeybees inside the lower part of Lancashire boiler or an external furnace of bolier. * Ensure that blow down of all boilers in battery are not connected together. Inspector can refuse the inspection under Section 14(2) and report to the Director immediately. ‘© Confirm that fuse of feed water pump is removed. Be sure that boiler is isolated from battery of boilers only then carry out inspection otherwise Inspector can refuse the inspection of boiler under Section 14(2) and submit report to Director accordingly, ‘+ While entering in the boiler for inspection confirm whether burner fuse is removed or not, in small or big oll fred boiler & then carry out inspection. * In petroleum industries C.O. (Carbon Monoxide) is used as fuel in boiler. While carrying inspection of such boilers confirm that C.O. gas is not in the boller & verify that C.O. gas valve is completely closed. Carbon Monoxide gas is very dangerous as it is odorless, * tthe time of hydraulic test of boiler take 1% times certified pressure, Due to high pressure of water, see the pressure on pressure gauge in control room while carrying hydraulic test in power boiler. If satisfied reduce the pressure than certified & then enter in boiler. Due to high pressure do not carry out hammer test, Because of high pressure there is a possibilty of jet being thrown out © While carrying steam test of solar boiler do not pass between mirror and collector, due to the high temperature. Ensure that prohibitory arrangement is made in such cases. Use ear mask or plug while carrying steam test. Due to heavy sound there is a possibility of becoming deaf for ever. Indian BOE Exam Guide Book (Edition-1) Author : MITHILESH SINGH, mobile: +91-9827482029, EmailPART-B[Boiler Engineering(Paper-1&2)] 2 Precautions before starting the Fires Before starting the fires in a boiler the attendants should— (1) See that here is sufficient water in the boiler and that the gauge cocks are working freely; (2) Ease safety valves, or open cock on top of boller to allow air to escape ; (3) See that the blow-off cock is fully closed and tight; (4) See that safety valves and fee check valve are free and workable; (6) Note if the pressure gauge pointer is at zero; (6) See that the feed pump is in working order’ He must not rely on the supposition that the waler he has previously put init stil in the boiler, as it may have run out without the knowledge through a leak or open cock, nor can he be sure that the gauge glass shows the true water level until he has tested it. This is done in the following manner; shut off the lower gauge cock and empty the glass by the drain cock; then shut the drain cock and open the gauge cock; if everything is in order, the water will then rise in the glass to the same height as before. Raising steam:-in getting up steam in all types of bollers, the operation should be as gradual as circumstances will allow. Nothing turns @ new boiler into an old one sooner than getting up steam too quickly. Forcing the fires when starting work is liable to cause straining of the steams and tubes of the boller. In the case of large boilers generally steam should not be got up in less than six hours. Before getting up steam the water level should be observed, to ensure that water is at the proper heights, in the glass, the pressure gauge noted and the safety valves tried to see they are free, The blow-off cock should be examined to see that itis completely shut and tight. Pressure gauge :- The pressure or steam gauge should be kept in order and be in such a position as to be easily seen by the boiler attendant, There should be a plain mark on it showing the highest pressure allowed for the boller and the dial should be kept clean so that the figures may easily be read. ‘Steam pressure : Ordinarily, the safety valves will prevent the steam from rising much above the working pressure, but if the steam gauge shows is rapid an increase of pressure as to indicate danger of exceeding the highest limit, water should be immediately fed into the boiler, and the dampers partially closed in order to diminish the effect of the fire. If however, the water has fallen so low that there is danger of an accident from this cause the fires should be withdrawn before feeding in water the safety valves eased and If the engine is at rest it should be started so as to reduce the pressure, The safety valves are provided to guard against over-pressure. They should be moved by hand every day so as to prevent them from sticking. If moved only occasionally, they are liable to leak. The valve can be tested by slowly raising it alittle and when let down, it should closed perfectly tight. It should never be opened by a ‘sudden knock or pull. If it does not closed tight turn it on its seat not permit this, rise it slowly a few times and let it down again, but on no account must the valve be screwed down further or loaded more than what has been allowed by the Inspector. Safely valves must never be over-loaded and spring valve should have ferrules or other provisions against the valves being ‘screwed down too far. In case of an accident resulting from will full overloading culprit might be held criminally responsible at the official inquiry or inquest. inti i first, or when its construction does Indian BOE Exam Guide Book (Edition-1) Author : MITHILESH SINGH, mobile: +91-9827482029, Email : mithlleshkhudawalOgmall.comPART-B[Boiler Engineering(Paper-1&2)) 3 Low water safety valves : If there is low water safety valves, test it occasionally by lowering the water level to see that valve begins to blow at the right point. It should give warning "before” the water level has Sunk too low and before damage can be done when the boiler is open, examine the floats and lever and see that they are free and that they give the valve the full rise. With the ordinary type of high steam and low water safety valve the float should be down at its lowest position and the valve full open when the boller is empty. ‘The water gauge :- These will be kept in best order by frequently blowing through. The cocks are thus kept in good working condition without leaking, Blow through the drain cock at the bottom of the gauge land shut and open the steam and water cocks every few hours. These cocks should be blown through more frequently when the water is dirty. Should either of the passage become choked, or whenever the water in the gauge glass moves sluggishly the passage must be cleaned. This is best done with a wire. The gauge glass is so arranged that its top cock connects with the steam space and its bottom cock is below the water line, The water line will ordinarily be near the middle of the glass tube. Always test the glass water gauges thoroughly the first thing in the morning and at the commencement of every shift. This Is done by first opening rain cock and then shutting the upper cock which should give water; the upper ‘cock should then be opened and the bottom cock closed which should give steam during this test the drain cock should be kept open. If water and steam do not appear in proper order the cocks are choked and the passage should be cleaned. To lessen the risk of breaking the gauge glass the water cock should ‘always be reopened after the steam cock. Gauge glasses with a narrow white strip running the whole length of the glass on the side next the boiler are recommended as they show the water line more clearly specially when the water is dirty. The boiler regulations framed by the Board require every water gauge glass to be fitted with, a guard to prevent injury to the attendants, See that itis always in place and clean when there is steam in the boiler. Special Note :- It does not follow that there is plenty of water in the boiler because there in plenty of water in the gauge glass. The passages may be choked and empty gauge glasses are some times mistaken for full ones and explosions have resulted therefrorm. Hence the importance of keeping the gauge, cocks perfectly tight and clean and of blowing through the test cocks frequently. A large number of accidents have been due to inoperative water gauges and to negligence of the attendants in not carefully reading the water level The blow-off cock :- The blow-off should be used daily if the water is at all dirty or sedimentary, especially with Locomotive type and Vertical Boilers as their narrow waler spaces are liable to get choked with mud, which soon hardness into a solid mass. The amount of water to be blown out depends on the size of the boiler and can be determined only from experience. When blowing out the best result is obtained if the water has been at rest for some time ( say before the engine is stared) thus giving the sediment time to settle; if the feed waters cleaned merely turn the cock round. The scum cock :- When scum cocks are fitted, if the feed water is dirty, a litle should be blown off daily if the water is clean, merely turn the cock round. Before opening the scum cock, see that the water is at the height indicated by the water level pointer; otherwise the scumming will be ineffective. Water should bbe blown from the surface through the scum cock when steam Is being drawn off, i.e. when the engine or other machinery is working. Indian BOE Exam Guide Book (Edition-1) Author: MITHILESH SINGH, mobile: +91-9827452029, Email: mithileshkhudawal@gmaPART-B[Boiler Engineering(Paper-1&2)] 4 Manhole and other door joints.- When making such joints the jointing materials should never be of round sectioned packing. Care must be taken that the spigot of the door is centrally placed in the hole, as many accidents have resulted from packing being blown out between the spigot and side of hole, even when the clearance was only 3 mm, The nuts must be carefully and evenly tightened. Further tightening should be made during the process of heating up the boiler when raising steam. ‘Steam-pipes :- When properly arranged should give no trouble. Frequently however, they are so designed as to contain pickets, in which, while out of use, condensed steam accumulates. Such water is exceedingly, dangerous and great care should be taken to see that the pipes are properly drained before the stop-valve is opened otherwise "water hammer’ will take place even with the best designed steam pipes, and disastrous explosions causing loss of life and property may occur. ‘Scale and grease :- Roughly speaking, scale offers a hundred times as much resistance to the passage of heat as does a similar thickness of the steel or iron. A 12mm furnace plate covered with 2 mm. scale is as efficient a heat retarder as steel furnace 250 mm thick. Grease is about ten times worse than scale. In ‘a boller at work the temperature of a clean furnace plate is only slightly in excess of that of the water in tne bolle; but is scale or grease is interposed between the water and the plate, the latter acquires a temperature more nearly approximately that of the flame with which itis in contact. If the fire is fierce (artificial draught) the furnace tube may grow so hot that it elongates considerable. If in addition, cold air is admitted during each firing, a concerting action of the furnace takes place, which is one of the worst causes of boiler wear and tear. Wear and Tear can be reduced and the life of a boiler prolonged if scale and grease are prevented from accumulating in a boiler. The combined effects of scale or grease and artificial draught are disastrous. Scale or grease also causes waste of fuel Grease :~ A mixture of sedimentary water , soda and grease produces an adhesive scum, Where this is suspected, the water level should never be lowered below the furnace top unless the boller is afterwards entered and this scum cleaned off the furnace plate before the firing again Scale removal :- The customary method is not a salisfactory one. The boller is emptied and then cooled down by opening all the manholes, and the esult is that the scale which would otherwise be soft, hardens through contact with the air and requires laborious chipping off. A very effective, but slower method is to retain the water in the boiler until cool, and not to run it out until the men are ready to enter the boiler with water house brushers and scrapers, The scale will then be soft and easily removable. If time is a consideration, the cooling can be accelerated by adding cold feed to the hot water in the boiler and slowly running off the cold water. Another method is to blow off the boiler with the lowest possible pressure (not more than 1 Kilogram per sq.cm) and to keep it closed until cold. The scale will then be easily removed. Treatment of feed water :- Many feed waters require soda or other chemicals to arrest corrosion or to change the nature of the scale. There is no harmless chemical which will remove scale or sediment when Ithas once got into the boller and the only effective process is to purify the feed water before it enters the boiler. By this means, the sediment, and generally 100, the added chemical, can be deposited in tanks or in fiters, and therefore never goes into the boller, excepting when the water obtainable is very good, water-purifying apparatus ought to pay any boiler-owners, particularly at those works where three or more boilers are in constant work. Boller Owners wishing to have definite advice as to the best treatment of their feed water should have it analyzed at some chemical laboratory and ascertain the best treatment in Indian BOE Exam Guide Book (Edition-1) Author : MITHILESH SINGH, mobile: +91-9827482029, Email : mithileshkhudawal@gmall.comPART-B[Boiler Engineering(Paper-1&2)] 5 the particular circumstances. Special attention is drawn to the not in frequent but very bad practice of allowing the waste steam from the Engine Cylinders or Pumps to be drained into the Boiler Fed Water Tanks. The waste steam from cylinders is always mixed with a certain amount of oily matter which will be deposited in the feed water tanks and ultimately be pumped into the boiler, with possible disastrous results, as it will be obvious to every careful boller attendant that should the oll be deposited on the furnace crowns, they may become overheated and collapse. It should be the first care of the boiler-owner, and the Boiler Attendant to see that the feed water is kept as pure as possible. Impure feed water means additional expense on the upkeep of the boiler. Preservation of boilers when not in use :- steam bollers, when not in use are liable to deterioration from corrosion and unless well cared for and made rust-proof; they may depreciate more rapidly than when in use. They should be thoroughly drained and thoroughly dried and all valves, cocks and openings closed so as to exclude moisture. Another plan is to fill the boller with water to which about 1/100 per cent caustic soda has been added. Special instructions for Boiler.:- Boiler should be opened up and thoroughly cleaned after a period of work which should not exceed (as indicated in certificate.) A record of such cleanings should be maintained and produced, when required by the Inspector. B/2.FUELS ‘TYPE OF FUELS 1. Solid 2. Liquid 3. Gaseous. Liquid fuels properties : Density : Density is defined as the ratio of the mass of the fuel to the volume of the fuel at a reference temperature of 15°C. Density is measured by an instrument called a hydrometer.The unit of density is kgim3. (ii) Specific gravity :This is defined as the ratio of the weight of a given volume of oll to the weight of the same volume of water at a given temperature. The density of fuel, relative to water, is called specific gravity. Specific gravity is a ratio it has no units. The measurement of specific gravity is generally made by a hydrometer. Specific Gravity of LOO Is 0.85 - 0.87, Furnace oil 0.89 - 0.95 &L.S.H.S (Low Sulphur Heavy Stock) is 0.88 - 0.98 if) Viscosity :The viscosity of a fluid is a measure ofits internal resistance to flow. Viscosity depends on the temperature and decreases as the temperature increases. Viscosity is measured in Stokes / Centistokes. Viscosity is also quoted in Engler, Saybolt or Redwood. The measurement of viscosity is made with an instrument called a Viscometer, (iy) Flash Point :The flash point of a fuel is the lowest temperature at which the fuel can be heated so that the vapour gives off flashes momentarily when an open flame is passed over it. The flash point for furnace oll is 68 *c. () Pour Point :The pour point of a fuel is the lowest temperature at which it will pour or flow when ‘cooled under prescribed conditions. It is a very rough indication of the lowest temperature at which fuel oil is ready to be pumped. (vi) Specific Heat :Specific heat is the amount of kCals needed to raise the temperature of 1 kg of oil by 10C. The unit of specific heat is kcal/kgOC. it varies from 0.22 to 0.28 depending on the oil specific gravity. The specific heat determines how much steam or electrical energy it takes to heat oil to a desired temperature. Light oils have a low specific heat, whereas heavier ols have a higher specific heat. Indian BOE Exam Guide Book (Edition-1) Author : MITHILESH SINGH, mobile: +91-9827482029, Emall : mithlleshkhudawal@gmall.comPART-B[Boiler Engineering(Paper-1&2)] 6 (vii)Calorific Value It is a measure of heating power of a fuel. itis the quantity of heat liberated when unit weight of solid or liquid fuel or unit volume of gaseous fuel is completely burnt in A. Gross Calorfic Value (G.C.V,) or Higher Heating Value of Coal: I's the {otal Neat that is berated by complete combustion of unit weight of coal at constant volume in Bomb Calorimeter. The products of combustion are cooled to 25°C and water vapour generated condenses. So GCV includes of condensation of water vapour. B. Net Calorific Value or Lower Heating Value: This is concerned with fuels containing hydrogen. In practice like in boilers, water vapour leaves the system and so its sensible heat and latent heat of vaporization is not available for use. Net C.V. Is Gross C.V. minus this unavailable heat being 1055 BTUILb, , Useful Heat Value (U.H.V.): GCV includes constituents viz. Volatile Matter and gross Moisture, UHV of coal is that heat which Is gainfully utilized in bollers. It is used in commercial practices. Formulae related to G.C.V, i), For Low Moisture Coals (ie. M < 2%) 4.8. Q = 165 F + 136(V-0.1A)-108M ii) For High Moisture Coals 18a 84(100-(1.1 A*M)] - 108M Where Q=G.C.V., Keallkg, A= Ash %, M=Moisture, % ,F = Fixed Carbon, % Formulae related to N. C.V. Net C.V. (kcal/kg)= G.C.V. (kcal/kg) 53 H Where H = Total Hydrogen, Including hydrogen of moisture and of water of constitution Formulae related to U.H.V ULHLV. (Keallkg}=8900-138 (A+M) (ity SulphurThe amount of sulphur in the fuel oil depends mainly on the source of the crude oll and to a lesser extent on the refining process. The normal sulfur content for the residual fuel oil (furnace oll) is in the order of 2 - 4 %. Percentage of Sulphur in Kerosene oil is 0.05 - 0.2, Diesel Ollis 0.05 - 0.25, L.D.O is 0.5- 1.8 , Furnace Oil is 2.0 ~ 4.0 & LSHS is less than 0.5. The main disadvantage of sulphur is the risk of corrosion by sulphuric acid formed during and after combustion, and condensation in cool parts of the chimney or stack, air pre-heater and economizer. (ix) Ash Content :The ash value is related to the inorganic material or salts in the fuel oil. The ash levels in distilate fuels are negligible. Residual fuels have higher ash levels. These salts may be compounds of sodium, vanadium, calcium, magnesium, silicon, iron, aluminum, nickel, etc. (x) Carbon Residue :Carbon residue indicates the tendency of oil to deposit a carbonaceous solid residue on a hot surface, such as a bumer or injection nozzle, when its vaporizable constituents evaporate. Residual oil contains carbon residue of 1 percent or more. (xi) Water Content : The water content of furnace oll when it is supplied is normally very low because the product at refinery site is handled hot. An upper limit of 1% is specified as a standard. 2. Solid Fuel (like Coal) Analysis of coal :There are two methods to analysis of coal 4. Ultimate analysis 2. Proximate analysis 1, Ultimate analysis : The ullimate analysis indicates the various elemental chemical constituents such as carbon, hydrogen, oxygen, sulphur, etc. It is useful in determining the quantity of air Indian BOE Exam Guide Book (Edition-1) Author : MITHILESH SINGH, mobile: +91-9827482029, Emall : mithileshkhudawalQgmall.comPART-B[Boiler Engineering(Paper-1&2)] 7 required for combustion and the volume and composition of the combustion gases. This Information is required for the calculation of flame temperature and the flue duct design eto, 2. Proximate analysis : The proximate analysis indicates the percentage by weight of fixed carbon, volatiles, ash, and moisture content in coal. The amounts of fixed carbon and volatile combustible matter directly contribute to the heating value of coal, Fixed carbon acts as a main heat generator during burning. High volatile matter content indicates easy ignition of fuel. The ash content is important in the design of the furnace grate, combustion volume, pollution control equipment and ash handling systems of a furnace, (i) Measurement of moisture:The determination of moisture content is carried out by placing a sample of powdered raw coal of size 200- micron size in an uncovered crucible, which is placed in the oven kept at 108+2 oC along with the lid, Then the sample is cooled to room temperature and weighed again. The loss in weight represents moisture. (i) Measurement of volatile matter:A fresh sample of crushed coal is weighed, placed in a covered crucible, and heated in afurnace at 900 + 15 oC. The sample is cooled and weighed Loss of weight representsmoisture and volatile matter. The remainder is coke (fixed carbon and ash), Measurement of carbon and ash :The cover from the crucible used in the last test is removed and the crucible is heated over theBunsen burner until all the carbon is burned, The residue is weighed, which is theincombustible ash. The difference in weight from the previous weighing Is the fixed carbon, (iv) Fixed Carbon or FC derived by subtracting from 100 the value of moisture,volatile matter and ash, Storage, handling and preparation of coal :Storing coal has its own disadvantages like build-up of inventory, space constraints, deterioration in quality and potential fire hazards. Other minor losses associated with the storage of coal include oxidation, wind and carpet loss, A 1% oxidation of coal has the same effect as 1% ash in coal. Wind losses may account for neariy 0.5 ~ 1.0 % of the total loss, The main goal of good coal storage is to minimize carpet loss and the loss due to spontaneous combustion. Formation of a soft carpet, comprising of coal dust and soil, causes carpet loss. On the other hand, if the temperature gradually rises in a coal heap, then oxidation may lead (0 spontaneous combustion of coal stored. Carpet losses can be reduced by: 1. Preparing a hard solid surface for coal to be stored 2. Preparing standard storage bays of concrete and brick 3. Gaseous Fuel : Types of gaseous fuel The following is a list of the types of gaseous fuel Fuels naturally found in nature: 1. Natural gas, 2. Methane from coal mines Fue! gases made from solid fuel 1. Gases derived from coal 2. Gases derived from waste and biomass 3. From other industrial processes (blast furnace gas) Gases made from petroleum 1. Liquefied Petroleum gas (LPG) 2.Refinery gases 3.Gases from oll gasification Gases from some fermentation process Properties of gaseous fuel Relative Density Higher Heating Value keal/Nm3 Air/Fuel ratio maof air to m3 of Fuel Flame Temp.oC Flame Speed m/s Indian BOE Exam Guide Book (Edition-1) Author : MITHILESH SINGH, mobile: +91-9827482029, Email : mithileshkhudawalagmail.comPART-B[Boiler Engineering(Paper-1&2)] 8 B/3.COMBUSTION OF FUEL Combustion process Combustion process means oxidation of fuel in presence of heat. Complete combustion of a fuel is possible only in the presence of an adequatesupply of oxygen. Oxygen (02) is one of the most common elements on earth making up 21% of our air.Rapid fuel oxidation results in large amounts of heat. Solid or liquid fuels must be changed toa gas before they will burn. Usually heat is required to change liquids or solids into gases. Most of the 79% of air (that is not oxygen) which is nitrogen, with traces of other elements. Nitrogen is considered to be a temperature reducing diluter that must be present to obtain theoxygen required for combustion. Nitrogen reduces combustion efficiency by absorbing heat from the combustion of fuels ~anddiluting the fiue gases. Three T’s of combustion Homogeneous mixture of carbon and oxygen content is important. To ensure good combustion is controlling the “three T's" of combustion which are (1) Temperature high enough to ignite and maintain ignition of the fuel, (2) Turbulence or intimate mixing of the fuel and oxygen, and (3) Time, sufficient for complete combustion. Too much, oF too little fuel with the avallable combustion air may potentially result inunburned fuel and carbon monoxide generation. A very specific amount of O2 is needed forperfect combustion and some additional (excess) air is required for ensuring completecombustion. However, too much excess air will result in heat and efficiency losses. Usually all of the hydrogen in the fuel is burned and most boiler fuels, allowable with today's air pollution standards, contain little or no sulfur. So the main challenge in combustion efficiency is directed toward unburned carbon (in the ash or incompletely burned gas), which forms CO instead of CO2 Perfect, good and incomplete combustion : Below mention three comparative figures are showing the difference combustion process with changing of air & fuel ratio HEAT CO iM Hoot Je oe penrecT / C ~ INCOMPLETE ~~ Caer zp x tomausTion (somBustion_ gXZal \oNhs Ie =) a EPA. ar Combustion Controls Combustion controls assist the burner in regulation of fuel supply, air supply, (fuel to air ratlo), and removal of gases of combustion to achieve optimum boiler efficiency. The amount Cf fuel supplied to the burner must be in proportion to the steam pressure and the quantity of. steam required. The combustion controls are also necessary as safety device to ensure that the boller operates safely, Various types of combustion controls In use are: 4. On/Off control: The simplest control, ON/OFF control means that either the burner is firing at full rate or itis OFF. This type of control is limited to small boilers. 2. High/low/off control: Slightly more complex is HIGH/LOWIOFF system where the burner has two firing rates. The burner operates at slower firing rate and then switches to full firing as needed. Burners can also revert to the low firing position at reduced load. Indian BOE Exam Guide Book (Edition-1) Author : MITHILESH SINGH, mobile: +91-9827482029, Email : mithileshkhudawal@gmall.comPART-B[Boiler Engineering(Paper-1&2)] 9 This control is fitted to medium sized boilers. 3. Modulating control: The modulating control operates on the principle of matching the steam pressure demand by altering the firing rate over the entire operating range of the boiler. Modulating motors use conventional mechanical linkage or electric valves to regulate the primary air, secondary air, and fuel supplied to the burner. Full modulation means that boiler keeps firing, and fuel and air are carefully matched over the whole firing range to maximize thermal efficiency. Concept of Excess Air For optimum combustion, the real amount of combustion air must be greater than that required theoretically. Optimization is most important in the view of complete combustion, It can be monitored by residual oxygen content in flue gas. Theoretically no oxygen content should be in flue gas because it is leading to more heat loss from furnace. But practically it not possible to maintain zero excess oxygen content because there must be few content of oxygen to ensure complete combustion. If We try to maintain higher oxygen content in flue gas then possibilty of complete combustion is more the other part is that heat loss will be proportionally higher. Hence to ensure minimum heat loss along with complete combustion slight part of oxygen content should be indicated in Orsat apparatus for oxygen ‘monitoring. Excess air is nothing but a higher content of air more than that the calculated theoretical air Higher excess air means itis leading to heat loss but lowering of excess alr is leading to poor combustion. Hence optimization is most important factor in combustion point of view. B/4.DRAFT SYSTEM ‘The function of draft in a combustion system is to exhaust the products of combustion, ie. flue gases, into the atmosphere. The draft can be classified into two types namely: 4.Natural draft 2.Mechanical draft 4.Natural draft Natural draft is the draft produced by a chimney alone. Itis caused by the difference inweight between the column of hot gas inside the chimney and column of outside air of thesame height and cross section. Being much lighter than outside air, chimney flue gas tends torise, and the heavier outside air flows in through the ash pit to take its place. Draft is usuallycontrolled by hand-operated dampers in the chimney and breeching connecting the boiler tothe chimney. Here no fans or blowers are used. The products of ‘combustion are discharged atsuch a height that it wll not be a nuisance to the surrounding community. 2.Mechanical draft Itis draft artificially produced by fans, Three basic types of drafts that are applied are: (i) Balanced draft: Forced-dratt (F-D) fan (blower) pushes air into the furnace and aninduced draft (|-D) fan draws gases into the chimney thereby providing draft to removethe gases from the boiler. Here the pressure is maintained between 0.08 to 0.10 in. ofwater gauge below almospheric pressure in the case of boilers and slightly positive forreheating and heat treatment furnaces (i) Induced draft: An induced-draft fan draws enough draft for flow into the furnace,causing the products of combustion to discharge to atmosphere. Here the furnace is keptat a slight negative pressure below the atmospheric pressure so that combustion air flowsthrough the system. (ii) Forced draft: The Forced draft system uses a fan to deliver the air to the furnace, forcingcombustion products to flow through the unit and up the stack. Indian BOE Exam Guide Book (Edition-1) Author : MITHILESH SINGH, mobile: +91-9827482029, Email : mithileshkhudawaldgmall.comPART-B[Boiler Engineering(Paper-1&2)] B/5.TYPES OF BOILERS : Difference between Boiler & Steam Generator Boiler :A steam boller consists of the containing vessel and convection heating surfaces only. ‘Steam Generator: A steam generator covers the whole unit, encompassing water wall tubes, super heaters, Air pre heaters and Economizers. Types of Boiler : (a) On the Basis of Firing : (i) Fired boiler i.e, AFBC,CFEC,PFBC (ii) Non-fired boiler i.e. WHRB (b) On the Basis of heat source (i) Fuel fred boiter (i) Waste heat boiler (il) Electric power boiler (iv) Nuclear power boiler (c) On the Basis of Prossure (i) Low pressure Boiler <1.021atm(103.427KNim2) (i) Power Boiler >1,021aIm (ii) Miniature Boiler >/ 6.8 atm(689.7kNim2) (d) On the Basis of Nature of fuel (i) Coal fred (PF, Stroker, hand fired) (i) Gas fired (ii) Oi fired (iv) Wood fired/Biomass fired (v) Bagasse fired {e) On the Basis of Type of Furnace : 1, Duch Oven Boiler 2. Open Boiler 3, Scotch Boiler 4, Screened Boiler 5, Twin Boller (f) On the Basis of shapes & design features : 1. Water tube Boiler (i) Horizontal /Straight tube(boxed header type & sectional header type) (i) Bent tube boiler(Mono-drum,bi-drum,tri-drum,quadri-drum type) 2, Fired tube Boller (i) Short fre box type (ii) Compact type (i) Vertical tube type Indian BOE Exam Guide Book (Edition-1) Author : MITHILESH SINGH, mobile: +91-9827482029, Email : mith 10Engineering(Paper-1&2)] cE (iv) Horizontal type (v) Locomotive (vi) Scotch type. (g) On the Basis of Manufacturer Name 41. Benson boller 2. Sulzer boiler 3. La Mont Boller 4, Velox boiler 5. Loeffler boiler 6, Babcock boller 7. Wileox boiler 8. Yarrow boiler 9. Manning boiler 10. Thornycraft boiler (h) On the Basis of Boiler water Circulation 1, Natural circulation Boiler 2. Forced circulation boller B/6. Precautions to be taken for starting a boiler and economizer from cold and banked (hot) fire condition Following precautions has to be taken care during starting a boller and economizer from cold and banked fire condition: 1. Ensure sufficient purging of boiler. Avoid priming, foaming& carryover. 3. Avoid secondary combustion in convection zone of boiler. 4. Maintain desired drum level 5. Avoid starvation of super heater tubes, 6. Clear all the entire permit which is taken previously. 7. Maintain desired dratt into the boiler. 8, Avoid steaming into the economizer. 9. Ensure recommended feed water quality inlet into the boiler. 10. Ensure healthiness of all mountings, ftings & accessories. 11. Ensure free expansion of boiler as per recommendation of manufacturer, which is downward or upward, 12. Ensure all the boiler parameters to be normal, 13, Follow the cold/hot startup curve of manufacturer. 14. Avoid thermal shock in the boiler. 18, Ensure all the protection & interlock to be in service, 16. Operate all the air vent & drain as per boiler manufacturer recommendation, 17. Never violate the rule of SOPs(Standard operating procedures), 18. Ensure all emission & combustion control equipment in service 19. Upto 30% MCR loading of boiler, drum level control should be operated in Single Element. 20. Operate the plant with skilled manpower only. Indian BOE Exam Guide Book (Edition-1) Author : MITHILESH SINGH, mobile: +91-9827482029, Email : mithileshkhudawalfgmail.comPART-B[Boiler Engineering(Paper-1&2)] 2 B/7. Need for periodic cleaning into the Boiler: In oll and coal-fired boilers, soot bulldup on tubes acts as an insulator against heat transfer. Any such deposits should be removed on a regular basis. Elevated stack temperatures may indicate excessive soot buildup. Also same result will occur due to scaling on the water side. High exit gas temperatures at normal excess air indicate poor heat transfer performance. This condition can result from a gradual build- up of gas-side or waterside deposits. Waterside deposits require a review of water treatment procedures and tube cleaning to remove deposits An estimated 1% efficiency loss occurs with every 22 °C increase in stack temperature. Stack temperature should be checked and recorded regularly as an indicator af soot deposits. When the flue gas temperature rises about 20 °C above the temperature for a newly cleaned boiler, itis time to remove the soot deposits. It's, therefore, recommended to installa dial type thermometer at the base of the stack to monitor the exhaust flue gas temperature. Itis estimated that 3 mm of soot can cause an increase in fuel consumption by 2.5% due to increased flue gas temperatures. Periodic offdine/online cleaning of radiant furnace surfaces, boiler tube banks, economizers and air heaters may be necessary to remove stubbom deposits. B/8.Economizer : Mechanical devices intended to reduce energy consumption, of to perform another useful function such as preheating a fluid. An economizer is a heal exchanger In boilers, economizers are heat exchange devices that heat fluids, usually water, up to but not normally beyond the boiling point ofthat fluid. Economizers are so named because they can make use of the enthalpy in fluid streams that are hot, but not hot enough to be used in a boiler, thereby recovering more useful enthalpy and improving the bolle's efficiency. They are a device fitted to a boiler which saves energy by using the exhaust gases from the boiler to preheat the cold water used to fil (the feed water) ‘A-common application of econorizers in steam powerplants is to capture the waste heat from boller stack gases (fue gas) and transfer ito the boiler feedwater. This raises the temperature of the boller feedwater, lowering the needed energy input, in turn reducing the firing rates needed for the rated boiler output. Economizers lower stack temperatures which may cause condensation of acidic combustion gases and serious equipment corrosion damage if care is not taken in their design and material selection. Procedure to be adopted in putting an economizer out of commission while the boiler is on steam Economizer tubes should be designed to withstand maximum attainable flue gas temperature when dry. This features, plus an economizer feed water bypass oop, allows the boiler to operate safely when the economizer is out of service. To maintain the economizer clean, adequately sized access doors should be specified to allow regular inspections, maintenance and repairs. Itit become necessary to keep the economizer in non-working conditions (for a month or more) then itis always preferable to keep it dry. For dry storage, the economizer should drained, cleaned and dried. Hygroscopic deposits should be thoroughly cleaned with a high pressure water spray to prevent fre side corrosion during shutdown, If the down time is small, wet storage is suitable. For wet storage , the economizer should be filled to the normal water level with treated and dearated feed water. An appropriate dosage of N2H4(Hydrazine) and NH2 and Sodium sulphite should be added to the feed water and boiler for one hour before supplying to the economizer. B/9.Boiler Scales Preventions MATERIALS AND METHODS Recorded Observation Description * Clean Tube Basically clean metal + Slightly Scaled Orange peel (bare metal and some spotty scale) + Moderately Scaled 1/82" Scale (continuous) + Heavily Scaled 1/16" + Scale (continuous) * Chipped Scale ‘Scale that is flaking and easily removed + Pitting Corrosion Localized rust, generally oxygen pitting * Under Deposit Corrosion Corrosion occurring under the scale Indian BOE Exam Guide Book (Edition-1) ‘Author : MITHILESH SINGH, mobile: +91-9827482029, Email : mithileshkhudawalfgmalPART-B[Boiler Engineering(Paper-1&2)] 3 Deposit and Scale Formation Mechanisms Deposition and scale formation in steam generating systems results from the fact that the solubility of the deposit forming saits decreases with increasing temperature and concentration. Some of the more commen constituents associated with deposition and scaling are: Calcium (Ca) Phosphate (PO4) Magnesium (Mg) Sulfate (S04) Bicarbonate (HCO3) SIlicate (S102) Carbonate (CO3) Iron (Fe) Without proper treatment of feedwater and boiler water, deposits and scale may form by one or a combination of the following mechanisms: 1. Precipitation of relatively insoluble feedwater hardness compounds either in the preboller and/or the boiler. Hardness should be controlled in the feedwater prior to reaching the boller and precipitated in the main body of boiler water in the steam and mud drums. Precipitation of solids will form hard deposits on heat transfer if allowed to adhere to these surfaces. 2, Improper selection or inadequate control of chemical sludge conditioners anddispersants. Chemical treatments utilize various mechanisms to condition and visperse precipitates and suspended solids formed in boiler water. Using to litle ofthe proper treatment chemical may not provide adequate conditioning and dispersion to prevent adherence to boiler metal, and over-feeding the chemical treatment may interfere withproper conditioning of suspended solids and prevent their removal from the boiler through blowdown. Any one of these conditions can lead to increased boller deposition tendencies. 3. Supersaturation and crystallization of relatively soluble dissolved solids at the heat transfer surfaces. The thin film of boiler water immediately adjacent to the primary healing surface tends to become mare concentrated with dissolved solids than the main body of boiler water, As steam bubbles are formed, they depart from the tube wall leaving solids behind which form deposits. 4, Increasing the concentration of suspended solids in the boiler water due to inadequate blowdown. Failure to properly perform blowdown results in more solids in contact withthe heat transfer surfaces increasing the potential for scale formation and carryover. 5. Accumulation of iron and copper oxides from corrosion by-products entering the boiler from the preboiler system or transported with the return condensate. These metal oxides not only form deposits, but they also may act as binders for other insoluble solids In the boiler water, further increasing deposit tendencies. In addition, they can contribute to electrolysis corrosion. 6. Oil or process contamination can adhere to boiler surfaces or increase adherence of boiler solids. Condenser leakage will contaminate condensate with hard water and chemical treatment chemicals, such as corrosion inhibitors, anti-foulants and biocides, Effects of Deposit and Scale Formation Deposits in the pre-boiler section can restrict water flow to the boiler, cause feedwater regulating valves to malfunction, decrease heat transfer in stage heaters and economizers, and contribute to under deposit localized corrosion. Deposits in boiler tubes can reduce circulation through tubes, This may enhance further deposit formation due to the reduction of the cleansing effect of circulating water on solids concentrating at heat transfer surfaces. Since deposits are poor conductors of heat, they retard heat transfer from combustion gases. As heat transfer is further retarded, boiler tube metal temperatures Increase. The approximate softening temperature of boiler tube metal is about 482.2 °C , Itheat retardation of boiler deposits causes this temperature to be reached, tube softening and rupture will ‘occur. However, even when deposit build-up may not be sufficient to cause tube failure, their insulating effect may stil result in reduced boiler operation efficiency and energy wastage by allowing excessive heat to exit the boiler with the stack gas. As discussed earlier, deposits may also lead to differential corrosion cells beneath their surfaces. The result is localized corrosion or pitting. If such corrosion is severe, boiler metal can become thinned and weakened, resulting in ruptures due to internal boiler pressure, Indirect Costs of Scale and Corrosion in a Boiler 1. Production downtime due to boiler tube failures 2, Excess chemical usage 3, Manual cleaning of the tubes during repair season Indian BOE Exam Guide Book (Edition-1) Author : MITHILESH SINGH, mobile: +91-9827482029, Email: mithileshkhudawal@gmall.comPART-B[Boiler Engineering(Paper-1&2)] 14 4, Acid cleaning of the boiler tubes 5. Replacement of the boiler tubes Methods of Corrosion Prevention Corrosion is rarely completely prevented in a steam generating system. Treatment programs and chemical controls are established to maintain corrosion within acceptable limits, The primary methods of corrosion prevention in steam generating systems are: 1, Close attention to chemical residual levels and the use of proper analytical procedures. 2. Addition of an alkali, such as caustic, to control pH/alkalinity of makeup water, Feed water, and boiler water within specific ranges. 3. Removal of dissolved gases by mechanical deaeration and chemical oxygen scavenger addition. 4. Use of oxygen scavengers which promote the formation of the protective magnetite films. 5. Neutralization of carbon dioxide and other acidic gases with neutralizing amines 6. Use of filming amines, where applicable, to form a protective film on the metal surfaces of steam condensate systems, B/10.RLA(Remnant life assessment) Test ‘The Residual life assessment through condition assessment followed by Non-destructive test consists of 41. Interviewing of the operation and maintenance personnel of the plant, 2, Reviewing relevant design, operation, maintenance, outage, history and fallure analysis and records available forthe boiler components 3, Quantitative condition assessment and identification of ertical component inspection are carried out on the base of history 4, Inspection plan which include non-destructive evaluation procedure will be made on the basis of high and low temperature components. 5. The health assessment of various components is carried out using appropriate field testing ike visual examination, dimensional measurement, in-situ metallography, hardness measurement, dye penetrant test, ultrasonic and magnetic particle test, video imagescopy, oxide scale measurement, hydrogen embritlement and any other specified tests Assessment of creep damage and other mechanical test will be done on post service samples of super heater tubes. The samples from various sections will be collected for various tests at laboratory including mechanical test, Findings requiring immediate atlention of plant authorities to facitate taking action are given at site itself forthe repair, Al the results are summarized to find the remaining ife of the components. The study provides the information to take the decisions lke repair/replace/run for further safe usefuiness of the pressure part components of the boiler. The following test methods are widely used on boiler pressure parts: + Visual inspection + Thickness & diameter measurement + Dye penetrant test + Ultrasonic flaw detection test + Magnetic particle inspection test + In-situ metallography/ replication + Hardness measurement + Fibroscopic inspection + Oxide scale measurement + Hydrogen embrittiement + Material grade identification + Tensile & Fiattening test + Radiography + Accelerated Creep rupture test + Deposit analysis + Weight loss analysis for tubes + Hanger inspection + Hydraulic test Indian BOE Exam Guide Book (Edition-1) Author : MITHILESH SINGH, mobile: +91-9827482029, Email : mithileshkhudawal@gmall.comPART-B[Boiler Engineering(Paper-1&2)] 15 B/11. Basics of Boiler Engineering: B/11.1 Properties of steam B/11.1.1 Specialty of Steam : Higher specific heat and latent of vaporization Higher heat transfer co-efficient Convenient of controlling & distribution. Cheap in cost and inert in nature. PEN B/11.1.2Steam generation process: ‘The generation of the steam takes place, when continuously heat being supplied to water & in this process following are the sequential consequences 1. First Step : Volume will slightly increases when initially increases the temperature of water. 2. Second Step : On further heating, water temperature will reach up to its bolling temperature. Boiling temperature will ncreases with increases of pressure. 3. Third Step : Later to boiling temperature, water temperature will remain constant, But the water will get vaporized & volume of steam will start increasing. Wet steam will generate in this process Until the whole water converted into the wet steam, 4, Fourth Step: On further heating, Steam temperature will remain constant and all the suspended water particles being converted into dry saturated steam. 5. Fifth Step : On further heating, the temperature of dry saturated steam start increasing & this superheated steam obeys the law of perfect gas. B/11.1.3Steam Phase Diagram: Critical point lines of | constant! pressure | Temperature Enna Indian BOE Exam Guide Book (Edition-1) Author : MITHILESH SINGH, mobile: +91-9827482029, Email : mithlleshkhudawaldgmail.comPART-B[Boiler Engineering(Paper-1&2)] 16 B/11.1.4 Category of heat: 1, Sensible Heat :The heat which is utlized to increases the temperature of any liquid is known as sensible heat. Sensible heat is known as liquid heat. 2, Latent Heat :The heat which is utlize the phase transformation of any fluid from liquid to gaseous Is known as latent heat. 540 Keals required to convert 1 Kg of water into steam, 3, Super Heat :The heat which is uflize the increment of temperature of saturated steam to superheated steam is known of superheat. Difference in temperature between dry saturated to superheated steam is known as degree of superheat (Final superheated temperature minus saturation temperature of steam), B/11.1.5Key parameters in steam table: P = Absolute pressure (bar or kPa) ts = Saturation temperature(*C) bf = Enthalpy of saturated liquid or sensible heat (Kikg) hfg = Enthalpy of latent heat of evaporation (Kika) hg = Enthalpy of saturated vapour(steam) Kjkg Sf = Entropy of saturated liquid (Ki/kg*K) ‘Sfg = Entropy of vaporization (Ki/kg"K) ‘Sg = Entropy of saturated vapour(steam) Ki/kg"K VE = Specific volume of saturated liquid (m3/kg) Vig = Specific volume of saturated vapour(steam) ma/kg B/11.1.6Definitions of steam properties: 1. Absolute Pressure : Absolute pressure=Gauge pressure + Atmospheric pressure [Atmospheric pressure=1.01325 bar] 2. Boiling point :Temperature of saturated vapour or also of equivalent water under the same pressure. Specific volume of steam :Volume occupied by in m3 by 1Kg of steam. Mass density or density of the steam :Specific mass of the steam in a volume of m3. 5. Specific enthalpy of liquid water :Specific heat, its the quantity of heat contained in 1 Kg of water according to the selected temperature. 6. Specific enthalpy of the steam :ltis the total heat contained in 1 Kg of steam. Sum of the enthalpy of the various states (liquid and vapour). 7. Latent heat of vaporization : Heal necessary to transform 1 Kg of equivalent water into vapour without change of temperature (thermal energy} necessary during the change of state liquid to the state vapour 8. Specific heat of steam :Quantity of heat necessary to increase the temperature of 1°C on a unit of mass of 1 Kg of steam 9. Dynamic viscosity :The viscosity of a fluid characterized the resistance to the movement of the fluid. ae Indian BOE Exam Guide Book (Edition-1) Author : MITHILESH SINGH, mobile: +91-9827482029, Email : mithileshkhudawaldgmall.comPART-B[Boiler Engine ing(Paper-1&2)] v7 410. Sensible heat of water :Amount of heal absorbed by 1kg of water at constant pressure heating from 0c to the saturation temperature Sensible heat "H’=MxCpxatki/kg Where, M=Mass of liquid in kg, Cp=Specific heat of the liquid & At=Rise of liquid temperature. 411. Critical pressure, Critical temperature & Critical point :During the steam generation process when pressure and saturation temperature increases the latent heat of vaporization is decreases and at point when latent heat becomes zero. That point is known as a critical point. At the ertical point density of water and steam willbe same. At the critical point water changed into steam without any adcition of latent heat Critical pressure 222 bar & Critical temperature 374.15°C are identified 12. Wetness Fraction :The ratio of mass of water vapour {o the total mass of wel steam containing itis called as wetness fraction. Wetness fraction denoted by 'y y=t-x where x= dryness fraction. 13. Melting point :The heat supplied to a Ice or solid, the temperature of sold will rise tilt just starts melting. The temperature will remain constant tl whole ice or solid convert into liquid. 0*e or 273°K called as melting temperature 14, Entropy(s) :Itis the measure of how much heat must be rejected to a lower temperature receiver ata given pressure and temperature. BIM1. 7Enthalpy (Total heat) of the steam: Heat absorbed by water from freezing point to saturation temperature as well as heat absorbed during the process of evaporation. Enthalpy of any steam'=Sensible heat (hf) + Latent heat (hfg)+ heat of degree of super heat (hsup) (2) Wet steam enthalpy h’= hftxhfg [where dryness fraction «will be <1] (b) Dry steam enthalpy ‘h’=hg=hf+hfg (where dryness fraction will 'x’ be equal to 1) (c) Superheated steam enthalpy ‘h’ = Total heat of dry steam+ heat of degree of super heat. =ntehfgtCpltsuptsat) 19*Cp(Tsup-Tsat) Where Cp=Mean specific heat at constant pressure for superheat steam [value of Cp for steam lies between 1.67 to 2.5 Kjkg"? Tsup= Final temperature of superheated steam, Tsat=Saturation temperature atthe given constant pressure. (Tsup-Tsat)= Degree of superheat, B/11.1.8Advantage of superheated steam: Following are the main advantages of superheated steam. 1. It contains more heat contents by virtue of which capacity to do work is also increased without increment in pressure. 2. Superheating can be done by rejectiwaste gases otherwise it will passed uselessly through stack, 3. Itwill improve thermal efficiency by increasing degree of superheat. 4, Degree of super heat is added advantage by virtue of which it can be cooled during expansion in any engine cylinder. 5. Moisture free steam become it reduction of erosion properties. Indian BOE Exam Guide Book (Edition-1) Author : MITHILESH SINGH, mobile: +91-9827482029, EmailPART-B[Boiler Engineering(Paper-1&2)] 18 B/11.1.9Temperature entropy diagram: T ‘S2 (Superheated) ‘84-81 : Pumping work S1(1" Vertical line) : Heating by feed water (Sensible heat addition), ‘S1(Horizontal ine) : Evaporation of water in boiler (Latent heat addition). '$1(2 Vertical line) : Superheating of steam (Superheat addition) 'S2-S3= Ideal expansion of steam in turbine. 'S2-S3'=Practical expansion of steam in turbine 'S3-S4= Ideal condensation of steam in turbine. S3'-S4=Practical expansion of steam in turbine B/11.1.10:Mollier diagram{Entropy Vs Enthalpy diagram] Mollier diagram is a graphical representation of steam table by which we can understand the change of properties of steam on change of heating. Following are the basic configuration of mollier diagram, () Specific entropy is plotted along the ordinate(X-axis) (ii) Specific enthalpy along the abscissa (Y-axis), Entire the diagram categorized into two portion: 1. Horizontal line referred as saturation curve 2. Lower portion(wet steam region) contains the value of wet steam. Upper portion(superheated steam region) contains the value related to superheated steam. Indian BOE Exam Guide Book (Edition-1) Author : MITHILESH SINGH, mobile: +91-9827482029, Email : mithileshkhudawal@gmall.comPART-B[Boiler Engineering(Paper-1&2)] 19 Mollier diagram has following four basic lines 4. Dryness fraction lines: The lines which is drawn in the wet steam region below the saturation curve. These lines represent the condition of wel steam between various values of enthalpy and entropy. Dryness fraction lines are slightly curved in horizontal direction. 2. Constant specific volume lines: The lines are drawn between wet steam region and superheated steam region. These lines reflect the specific volume of steam between the various value of enthalpy and entropy. 3. Constant pressure lines :The lines drawn in both the wet steam region and superheated steam region. These lines represent the pressure of steam between the various value of enthalpy and entropy. 4. Constant temperature lines :This line are drawn only in superheated region(above saturation curve). These lines represent the temperature of steam between various value of enthalpy and entropy. The temperature lines are slightly curved in the horizontal direction. B/11.2 Effect of impurities ‘The major troubles caused due to impurities into the boller are as follows. 41. Seale formation :Scale formation occurred due to presence of salts (mainly due to caleium and magnesium). Following reactions are responsible for scale formation in the boiler. Ca(HCO3) + Heat =>CaC03 ¢ (soft sludge) +cO2 #420 Mg(HCO3) + Heat =>MgCO3 ¥ (soft sludge) «C02 # H20 2. Corrosion : Internat reaction which is takes place corrosion are as follows 3Fe+4H20 => Fe304+4H2 2Fe+02+2H20 =>2Fe(OH2) The corrosion into the boiler pressure parts(.e. water wall, economizer, etc.) is caused by an acid or low pH in addition to the presence of dissolved oxygen and carbon di-oxide inthe boiler feed water. Carbonic acid form due to the carbon d-oxide comes out of bicarbonate on heating where it combines with the water to form weak acid The drawback of corrosion is pitting, grooving on metal surfaces which will reduce the strength of the metal and ultimately failure ofthe boiler tubes may occurred 3. Priming :Priming is the sudden discharge of water with steam from the boler.Itis just ike the bumping of water that repeatedly accompanies rapid heating on a open vessel Priming Is caused due to following reasons: 1, Improper designing of boler. 2, Improper method of fing 3. Overloading of boiler 4 5 ‘Sudden change in load. Combination of two or more above factors at same instant Priming can be reduced by following ways (i) By installation of steam purifiers. (ii) Lowering water level in boiler drum. (ii) Maintain constant load (Avoid pulsating steam demand), 4. Foaming :Foaming is the formation of small and stable bubbles into the boller water. Foaming is caused due to following reasons Indian BOE Exam Guide Book (Edition-1) Author : MITHILESH SINGH, mobile: +91-9827482029, Emaill : mithileshkhudawalOgmall.comPART-B[Boiler Engineering(Paper-1&2)] 20 1. Higher percentage of dissolved solid 2. Excessive alkalinity 3. Presence of oil in boiler water. Higher concentration of solids form smal size of steam bubbles. This type of bubbles are much more stable In nature , do not burst easily, The foaming contaminates the steam with desired ‘amount of boiler water which contains the corrasive salts. 5, Carryover :Boiler waler solids are also carried over in the moisture mixed with steam even when there is no indication of either priming or foaming, This type of process known as carryover. Carryover may be partly mechanical or partly chemical problem Whereas mechanical causes as follows, () Boller design (i) Higher water level in boiler drum. Gil) Overtoading in boiler. (iv) Fluctuation in toad on boilers. (v) Possibility of carryover will be more if steam storage space are too small in boiler drum. Normally steam from boiler carries 0.5 to 1.5% moisture in the form of mist or fog. In modern high pressure boiler carryover of moisture limited about 0.1%, 6. Caustic Embrittlement :Caustic embrittlement is the weakening of the boiler steel as a result of inner crystalline cracks. This is created due to long exposure of boiler steel to @ combination of stress and highly alkaline boiler water. ‘The caustic embrittlement takes place due to following reasons (Whenever boiler water has free hydroxide alkalinity and some quantity of slica Na2GO3+HOH => CO2 4+2NaOH i) Slow rate of leakage of boiler water through @ seam ora joint (ii) Very high stress of boiler metal at the point of leakage. : soy J bey ‘ f ne i : | nh ! ' i I | ws : i 4 ( { ‘ ' : cto PRoppRate concert Indian BOE Exam Guide Book (Edition-1) Author : MITHILESH SINGH, mobile: +91-9827482029, Email : mithileshkhudawaldgmall.comPART-B[Boiler Engineering(Paper-1&2)] 21 B/11.3 Boiler Engineering vital terms Bint. Circulation Ratio Circulation ratio =Mass of flow rate of circulating water/Rate of steam generation (k) =Ciws Circulation ratio forthe natural circulation type boiler isin the range of 4 to 30 Circulation ratio for the forced circulation type bolle is in the range of 3 to 10. Circulation ration for Once through boiler is (unit). Bit. 2Capacity of any power plant : P=[WxCVxnbentng)/[860x1000] Where P=Power Plant capacity in MW. W=Coal consumption by boiler per hours in ka V=Calortc value in Keallkg nb=Effciency of boiler NtEficiency of turbine ng=Effciency of generator 8/11.3.3Evaporation Ratio : ER=Mass of steam generation/Mass of fuel consumption For Coal fired boiler ER is about 6 &For oll fed boller ER is about 13, B/11.3.4 Equivalent Evapor: he amount of water evaporated from and at 100°C to produce dry saturated steam at 100*C by absorbing the same amount of heat as used in the boller under actual operating conditions. Meg: lactx(H-Hwt)/539_ Kgihr Where Me :quivalent evaporation. Mact=Actual mass of steam generated per unit mass of fuel burnt. HeTotal specific enthalpy of steam under operating conditions Keals/kg. Hut=Specific enthalpy of feed water kcalkg 8/11.3.5 Factor of Evaporation :Factor of evaporation to be multiplied with the quantity of steam produced under operating conditions to get the equivalent evaporation, f=(H-Hwt)'539 Indian BOE Exam Guide Book (Edition-1) Author : MITHILESH SINGH, mobile: +91-9827482029, Email : mithileshkhudawalgmail.comPART-B[Boiler Engineering(Paper-1&2)] 2 B/11.3.6 Top dryness :Top dryness Is the inverses of CR(Circulation ratio), Top dryness=1/CR B/11.3.7 HGI(Hard groove grind-ability Index : Sample of coal passed through a miniature pulverizer whether definite amount of energy is supplied to it. The usual value of coal HG! will be in the range of 50 to 60 for good bituminous coal. B/11.3.8 Reheat Factor (RF) :RF=Cumulative heat drop(isentropic)/Overall heat drop(isentropic) B/11.3.9 Shut-off pressure of pump: Shut-off pressure is the pressure when discharge valve of any pump to be fully closed & pump to be run at rated speed(tpm). At such condition discharge pressure of the pump is known as shut-off pressure. B/11.3.10 NPSH(Net positive suction head) :The value by which the pressure in the pump suction exceeds the liquid vapour pressure, is expressed as a head of liquid and it is referred to as NPSH This is the characteristics on which system is to be designed. The value of NPSH needed at the ‘pump suction to prevent the pump from cavitation is known as NPSHR(Net positive suction head required). NPSHRa N’ B/11.3.11 DNB(Departure to nucleate boiling :ONB in which steam bubbles no longer break away {rom the solid surface of the channel, bubbles dominate the channel or surface. DNB is known as transition boling, unstable film boiling and partial flm bolling B/11.3.12 Calculation for safe working pressure of any parts of a boiler: () — ForTube P=(28ty/D Where P= test pressure in kgimm2. D=Specific outside diameter of the tube. pecific wall thikness ‘$=Stress(kgimm2) which shall be taken as 40% of the specific mean tensile strength at room temperature. (ii) For Shell WP=[(t-2)xSxJ}/(CxD) Where WP=The working pressure in (bb/sq Inch. {=the thickness of shell plate in 32 of an inch, ‘S=The minimum tensile breaking strength of the shell plats in tons/sq inch, =the % of strength of the longitudinal seams of shell or ofa line of holes in the ‘Shell not fully compensated, whichever is least calculated by the methods here Alter described, Cris a co-efficient (2.75,2.83,2.9,3.0 or 3.3). De the inside diameter of the outer strake of plating of the cylindrical shell measured in Inches. Dished ends (subjected to internal pressure) WP=[15xSx(t-1)/R Where WP=The working pressure in ibb/sq Inch. ReInner radius of curvature of the end in inches, which shall not exceed the ‘external diameter of the shell, S=The minimum tensile breaking strength of the shell plats in tons/sq inch. he thickness of shell plate in 32” of an inch, Indian BOE Exam Guide Book (Edition-1) Author : MITHILESH SINGH, mobile: +91-9827482029, Email : mithileshkhudawalOgmall.comB/11.3.13 Ageing of boilers (As per Indian Boller Regulations-1950) : PART-B[Boiler Engineering(Paper-1 &2)] 2B a) Shell Type Boilers: w “ \n order to take the aging effect on boilers, the working pressure of the parts of them as calculated from the formulae in these regulations shall be reduced as per the table given below:- fae ofp exceocng 25 | 35 | 45 [+0 60 70 | 80 | 90 | oo | (eee =tetel seimmpenieivaing as jes /oo| m/w a) a [a] pressure percent, For those boilers the plates of which have already been cut and tested shall be given a further lease of life of fifty years from the date of the test of the boilers. The working pressure that shall be allowed after the testing shall be reduced as per the table given below:- Period after date of test 7 [Maximum workin, | 7 [allowed (percentage) b) Water Tube Boilers: - 0 w ‘The boilers which are operating at a temperature of 400°C and above including utility or industrial boilers and all boiler parts operating in the creep range of the boiler shall be non- destructively tested as per the table 1 given below after they are in operation for 1,00,000 hours for assessment of the remnant life of the parts; ‘The parts of a boiler when it completes a life of twenty five years are to be tested as per table 2 for assessment of the remnant lfe of such parts. If results are acceptable as per the standards laid down by the Central Boilers Board, a certificate shall be Issued by the Chief Inspector of Boilers for extending the life of the boiler for a further period of ten years or such less period as recommended by the Remnant Life Assessment Organization. This assessment of remnant life shall be carried out thereafter every five years by the organizations working in the field of boilers and remnant life and extension thereof alter such organization is approved by the Central Boilers Board. Such organization shall work in close coordination with the office of the Chief inspector of Boilers in the field of remnant lfe assessment and extension, The working pressure of such boilers may be reduced on the recommendations of such approved organization Notwithstanding anything contained in this regulation, for boilers working at @ pressure less than 50 kglcm®, such elaborate remnant life assessment is not mandatory. However, in such cases, drums and headers of such boilers shall be inspected by Ultrasonic testing, Magnetic particle testing and Dye penetrant test. B/11.3.14 Conditions for hydraulic test to be done in any boiler : 1 2. 3, Author : MITHILESH SINGH, mobile: +91-9827482029, Email Any newly erected boller. As per due schedule annual inspection.(low & medium pressure boiler once in a year while high pressure boiler once in a two year but after the one year of hydraulic test online test to be carried ‘out in presence of Boller inspectorate authorities. If any maintenance job carried out in any pressure vessel parts of the boiler. Indian BOE Exam Guide Book (Edition-1) mithileshkhudawaligmail.comPART-B[Boiler Engineering(Paper-1&2)] B/11.3.15Safety valve settings: Blow-down%=[Set pressure-Reset Pressure]x100/Set pressure Where Set pressure set by increasing/decreasing the tension of spring, Reset prossure=This Is a pressure at which safety valve will reset/settledown. Reset pressure can be sel by movement of compression screw in clockwise/anti-ciock wise direction, Usually blowdown in order of 2.5 to 4% B/11.3.16 Calculation of chimney height: (@) Calculation for chimney height for SPM(Suspended particulate matter) Chimney height H=7.4(2)°*" where Q=flow rate of SPM(kgihr) (b) Calculation for chimney height for SO» emission rate Chimney height H=140"° where Q=S0, emission flow rate(kgih) 24 his is a pressure at which safety valve will lit/puff. Set pressure can be Chimney height Table SN | Boiler Size in MW __| Stack height 1 <2t0Mw Chimney height H=14Q"" where G=SO; emission flow rate(kgihr) 2 | 2ioMw-500NW 220 meters 3 | >500MW [275 meters Chimney height is decided by some others factors also: 1, Aviation clearances by airport authorities. 2. CECB(Central environment control board) clearance. 3. Nearest any multi-complex or highest building. 4, As per draught requirement of boiler. B/11.3.17 Type of Valves :Valves are usually designed as per the application, Following are the different types of valves. 1. Isolating Valve () Gate valve (i) Plug valve (ii) Balt vaive (iv) Cock vaive 2. Regulating Valve (Globe vaive (i) Angle valve (ii) Needle valve (iv) Butterfly valve 3. NRV(Non-return Valve) (Swing check NRV (i) Lift check NRV 4, Safety Valve () Spring loaded safety valve (i) Dead weight safety valve (ii) Lever type safety vaive Indian BOE Exam Guide Book (Edition-1) Author : MITHILESH SINGH, mobile: +91-9827482029, Email : mithileshkhudawal@gmalPART-B[Boiler Engineering(Paper-1&2)] 5. Self Acting Valve () Ball float valve (i) Steam trap (a) Thermodynamic type steam trap (b) Mechanical type steam trap © Thermostatic type steam trap 6. Control Vaive () —Airto open control valve (i) Air to close control valve Bit. 25 18 Throttling of steam: During the throttling process steam expands from high pressure to lower pressure through a small opening(restricted opening). The heat transfer and work done are zero in this process. This process well known as ‘wire drawing’. During expansion the wet steam will start drying up even it may be superheated. During throttling process. () Nowork is done. (i) No heatis supplied or rejected, (ii) Total heat remains constant. B/11.3.19 Factors considered in designing of a boi Service requirements. Constant or variable load characteristics, Fuel burning characteristics Mode of fuel firing & burning, Hydrodynamics of gas flow, Feed water quality Furnace size, shape, material used for construction of furnace. Type of fumace bottom. Boiler operation Capital investment, is the main specification B/11.4 Gas cleaning devices Gas cleaning devices are mainly two types: 1. Mechanical type gas cleaning device [a] Dry type (i) Gravitational separator _{i) Cyclone separator [b]Wettype (i) Spray type (i) Packaged type (il) Impingement type 2. Electrical type gas cleaning device [a] Rod type {b] Plate type => ESP(Electrostatic precipitator) Comparative efficiency of dust collectors:~ 'SN__| Name of the device 7 [Cyclone separators Gas scrubbers [85.95% % Efficiency Evaporation capacity of steam in tones per hour at kgficm2 and at 100°C feed water temperature 2 3__| Fabric or bag filters ~ 4 [ESP ‘99% and above Indian BOE Exam Guide Book (Edition-1) Author : MITHILESH SINGH, mobile: +91-9827482029, Em: mithileshkhudawalégmalPART-B[Boiler Engineering(Paper-1&2)] 26 t-Sbra : chee ab SEE her PE hee bo. oth iz , J ROFTG Tp RFE ip panned Brow gl Re seruher abused div cet on arate id ree ad fm 46g top Rarmgl hep id -t62! qn Haielis wher wiy-ed wie APF Minis in Byeeyad te we vomwved dus) as eo! a WU ay SORE pproyeel veel SRF | pacticl “i Tn maint 2S rien lation siete patents aan % I ae ae FIG. sintern He e poh hae fannen Lika dey cyckone Akpere| “the voi pele theo. a oH 'e of peel Poi Anattes “Pas ap meio Ons to Phe. diac @ si pevuler fe SI ential imted maser “al fp He owt She Pproy sf = artiday —tyhad-He dud” effet dust _andSa, anc er + lk ot panda, (0% p down « o és kw ere Fy ta Stim callected at “Hee hettem sf pe wubey — Tha a a See out fam He top porte f As pew bey mete used te’ remove dust as well ax cectarn, Amount ot $05 - Indian BOE Exam Guide Book (Edition-1) Author : MITHILESH SINGH, mobile: +91-9827482029, Email : mithileshkhudawal@gmail.comPART-B[Boiler Engineering(Paper-1&2)] 27 3 Gravitationg| sebevatar> a BE ip coring om Re rape (prinsiple of - “Bere ave Hea Irate “pe of Govtietienal 6 D346. dunt laden gan in sponded wifk deob nd that atl ae poma dud bartele 5 ow velocity wilt bn & of. @ Placing {flea Reaviw partides polidy db Dinadvantegen 734 ean nov yemove i ard Reaview bartides con fea vemived dt j Yate i 4- Cydone scatter STE. dust tobe Laden Jie gas in allowed te amber a canitah ahetl qr vy pactticg up a pote lity rnbtion - Inte beady of gre eh a cat» lac _ Reaver poidheculele pilidx Any ‘ope (eeqartl | Ao hem a contnifegeelerce « Dank parties cal ea 0 “He betten we prpovated amt 1 Dust alteetion efficis Cees et eae dfn HR e Hae Bf Ihe dunt particles and th cts fanp of Binetic emmy a wa dwt porticlen Only Lanper ize JuddBy and enquired Sy Zone of interfere ote verde ) Pane vortex CD Low Maimtenmee cost be BP Noneftexi dle @ Higher ffreieny -| rer cian. ad particles + oe en ef ewe of! Ge High wfficteny at Raryhu howd : Ane Indian BOE Exam Guide Book (Edition-1) Author : MITHILESH SINGH, mobile: +91-9827482029, Email : mithileshkhudawal@gmail.comPART-B[Boiler Engineering(Paper-1&2)] 28 5. ESP(Electrostatic Precipitators) : Key features of ESP : 1, High installation cost but low operation cost. Low pressure drop. Less maintenance required No physical obstacle unlike bag fiters. Efficiency as high as 99.9%. Hot ESP can handle gas temperature as high as 350°C. Disadvantages of ESP : 41. Not suitable for high resistivity dust. 2. Efficiency fluctuate with process condition (Temperature & % moisture) to capture the dust, 3. Collection efficiency reduced at higher velocity of gas. Part list name of ESP: 1, Emitting electrodes. 2. Collecting plates. 3. Rapping mechanism, 4, Gas distribution screen 5. Support insulator 6. Transformer along with rectifier 7. Hoppers 8. Gas inlet and outlet duct. 9. Access door. 10. Purge blower. 11. Side wall & structure 12. Control panel 49. Hopper heaters etc. R Seeta Hair Principle of operation: # High DC ~ve potential is applied to discharge electrode with respect to grounded collecting plate, # Above di-electic strength, the break-down of medium takes place. # Discharge of free electrons from emiting electrode which move towards collecting plates, # lonize gas molecule & charges dust particle negatively Indian BOE Exam Guide Book (Edition-1) Author : MITHILESH SINGH, mobile: +91-9827482029, Email : mithileshkhudawaldgmail.comPART-B[Boiler Engineering(Paper-1&2)] 29 # These negatively charged dust particles moves towards collecting plate, gets collected Bloose their charge. Factors influencing the performance of ESP: [TALPROCESS - i Particle size distribution. | [6] METHOD OF OPERATION {Operation of Current transformer ii. Dust concentration i Rapping frequency ii, Dust resistivity i___Insulator heating iv. Temperature of gas TC] MECHANICAL CONDITION v. Moisture content/dew point i. Health of rapping mechanism vi. Gas distribution i Condition of electrode il Door sealing Tripping protection of ESP: ESP transformer should be tripped on following condition for protection of ESP. 1. Spark rate very high [about >20spark per minute] 2. ESP inlet temperature very low [about <110*C], 3. CO level very high [about 300ppm) 4, Hopper level very high B/11.5 Important topics, which may asked in BOE Exam B/11.5.1 Comparison between jet and surface condensé ‘Jet Condenser Surface Condenser 1 | Exhaust steam and cooling water are in direct contact with each other. 7 | Exhaust steam and cooling water are not directly in contact with each other. 2 | The condensate may nol be used as feed water, 2_| The condensate is generally used as feed water. 3 | Less suitable for high capacity of plant 3_ | Very high vacuum Gan be created so higher plant efficiency. 4_| Lesser quantity of cooling water is required. | 4 | Large quantity of cooling water Is reauired '5_| More power is required for air pump. 5_| Less power is required for air pump. 6 [tis simply and less costiy. €_| The cosily as compared to jet condenser, 7_[The maintenance cost is less T_| The maintenance cost is high | 8/11.5.2 AVT (All volatile treatment] completed without looking at the alternative to phosphate programs, This program use AVT(All volatile treatment) chemicals and is commonly referred to as AVT or zero solids treatment, Sodium is removed from the feed water by evaporation or demineralization of the makeup water and full flow, mixed bed demineralization of return condensate. No chemicals containing sodium are added for internal treatment. ‘The chemicals used are all volatile materials are ammonia and or Marpholene or cyclo-hexalamine for pH control and hydrazine, catalyzed hydrazine or a volatile hydrazine substitute as an oxygen scavenger and corrosion inhibitor. The contro! limits for an AVT program are total solids less than 2ppm and pH range of 8.5t09.0. Indian BOE Exam Guide Book (Edition-1) Author : MITHILESH SINGH, mobile: +91-9827482029, Emal review of high pressure boller water treatment would not be fullyPART-B[Boiler Engineering(Paper-1&2)] 30 B/11.5.3: APH(Air pre-heater) Fire Causes of APH(Air pre-heater) fire : APH fir may occur during cold startup on ll or startup following hot standby because of poor combustion of the oil fuel. This improper combustion result in unburnt or partially burnt oil condensing and depositing on the APH element surface. As the temperature entering the APH, increases this deposits baked to a hard vanish lke material. Theses deposits can ignite as temperature increases to 315 to 370°C range. Fire will unti the metal heat transfer element temperature reaches 730 to 765°C. Measures for preventing APH fire: Following are the precautionary measures by which APH fire can be prevented. APH dust leakage has to be eliminated SCAP(Steam coil air preheater) to be taken in service during cold startup of boiler. ‘Through maintain desired furnace pressure. Fire sensing devices to be always in service. Bypass APH during cold startup of boiler. ‘Through optimum level of oxygen & CO in flue gas. Bit 5. : Mili(Pulverizer) Fire Reason of Mill fire : Mil fire are mostly caused due to as follows Pyrite(Coal reject) buildup from pyrite flow failure, Hot startup with loaded mil. Accumulation of coal dust in mill services. Localized hot spots from poor primary air flow. ‘The causes of fires are also dependent upon coal properties(VM & Moisture) that exceed pulverizing rating. Wet coal always blocks feeders, reduces system input and produces a dangerously lean coal air mixture in the mill. Better coal handling method and effective trash separation could reduce feeder problems and the possibility of mill ie. Action to be taken during the Mill fire: The closing of multiport outlet valve can prevent the spread of fire from mill to burner lines. The three major types of quenching methods used are: 1. Water, 2. Steam & 3, CO2 injection. Uses of water has proved in adequate in some deep sealed mil fires. Steam injection is effective but a potentially explosive CO-H2 mixture may result from steam coke reaction. Indication of Mill firing 1. Mil outlet linetemperature will increase 2. Localized hot spots. 3. Chocking of pyrite hoppers. 4, Blocking of feeders (reduces system inpul), B/11.5.5: Reason of Economizer tube failure : 1. Pitting/Localized corrosion. 2, Low temperature corrosion. 3. Fly ash erosion. 4, Thermal fatigue. 5. Corrosion fatigue Indian BOE Exam Guide Book (Edition-1) Author : MITHILESH SINGH, mobile: +91-9827482029, Email: mithileshkhudawal@gmall.comPART-B[Boiler Engineering(Paper-1&2)] 31 B/12. Basics of strength of material: B/12.1 Basle theory : 1+ Stress - Resistance Against Deformation Numerically Stress (o) = Load(P) /Area(A) =P/(rr/4)d? I, 2-Strain (e) = Ratio of change in length(dl)/original length I) 3- Modulus of Elasticity [ Young Modulus] (E) = Stress(a) /Strain( e) Hooke’s Law- When materials loaded within elastic limit stress produced is directly proportional to Strain. = [Stress (6) x Length i)]/Elastic Modulus (E) 80x! /E=[Pxl]/AE Problems : An hollow circular mild steel column of external diameter of 300mm,internal diameter 250mm, carries an axial load of 1500 KN. Determine , compressive stress in column, if length of column is 3.75m. Find decrease in length of column. Take = 2.x 105 N/mm?, Solution : Given data P=1S0KN =2%105N/mm? Dy = 300MM Dj = 250MM L=3.75m =3,75x 10 mm a> Compressive stress o=2? Area = m/4 (Do?.Di2)= 1/4 (302.2502, A= 2159845 mm? So Compressive stress = P/A = 150x 10*/21598.45= 69.45 N/mm? bb >Decrease in length of column 8 = 69.45x3.75x 10" /2« 10° 1,302 mm 8/12.2 Bar of varying section: Question : Figure shows a bar consist of 3 length. Find 1+ Stress in all 3 parts. 2. Extension of an bar for an axial pull of 40KN. Take € = 2x 10° N/mm? Indian BOE Exam Guide Book (Edition-1) Author : MITHILESH SINGH, mobile: +91-9827482029, Email : mithileshkhudawal@gmail.comPART-B[Boil 1 8.2)] 32 r Engineering(Pape Solution stress in part AB = P/AL =40% 10°/ n/4x (30? ) = 56.58 N/mm? stress n part BC= P/A2 =40x 10° / 1 /4x (20? «127-4N/mm? stress in part CD = P/A3 = 40 102/ n/4 (22.5? .48.21N/mm? Now total elongation in bar, 8=2? We know, 5=PxI/AE =oxl/E 5.81. 82.5) = GHlI/E + onxI2/E Hox /E 8= VE (o)xI1 +0412 + 0.4) #1/2 10°(56.58180+127.4%260+48.21*160)=0.255 mm, 8/12.3Poisson Ratio, Lateral strain, Longitudinal strain & Volumetric strain: Poisson Ratio = Lateral Strain/Longitudinal Strain Lateral Strain = 6d/d ( Strain which acts along diameter or breadth) Longitudinal Strain = 1/1 (strain which acts along length) Volumetric strain = Change in volume original volume =8/v Relation between 3 modulus : Modulus of elasticity () 2. Modulus of rigiity(6) 3. Bulk modulus(k) E=26(1+1) E=3K(1-2}1)Where pis poisson ratio Question : A brass 12mm diameter is subjected to tensile test observation shows that In a gauge length of 82mm ‘elongation is 0.2mm under a pull of 30KN. The decrease in bar diameter is found as 0.0095mm. Determine 1. Modulus of elasticity. 2. Poisson's ratio. Solution : given that, d=12mm, l=80mm, 61=0.2mm, 8 d=0.0095mm & P=30KN Stress o=P/A=(30x10")/[(7/4)x(12)"]=265.26N/mm2 Linear stress [-0.2/80-0.0025, Modulus of elasticity E=c/e=265,26/0.0025=106104 N/mm Lateral strain=5d/d=0,0095/12=0.0008 Poisson's ratio w=Lateral strain/Linear strain=0.0008/0,0025=0.32 Indian BOE Exam Guide Book (Edition-1) Author : MITHILESH SINGH, mobile: +91-9827482029, Email : mithileshkhudawal@gmall.comPART-B[Boiler Engineering(Paper-1&2)] 33 8/12.4Thin Cylinders: Hoop stress: Its the stress which acts circurnferentially along an surface bar Hoop stress Oy.Pxd/2twhere P=Pressure, lameter & t=thickness. Longitudinal stress: Longitudinal stress acts parallel to the axis of shell ‘Thus, longitudinal stress © =Pxd/at Circumferential strain=@c=[0j—G>xp1]/E Longitudinal strain= €=[62~0 xH]/E Strain capacity=@v=2@,+@2 Increase in Volume=SV=eVXY Question: An cylinder air receiver for a compressor is 2meter diameter and mode of plates 1.5mm thickness. if circumferential (hoop stress) is not to exceed S0N/mm2 longitudinal stress is 60 N/mm2. Find the maximum safe air pressure in each. Solution: Given that, d=2m=2000mm, t=1.5mm, ec-90N/mm?2 & e;=60N/mm2 Hoop stress O=[Pxd]/2t Po[Gyx2t)/ '=[90x2x1.5]/2000=0.135 N/mm2 longitudinal stress aya P=[Oyx4xt]/d=[60x41.5]/2000=0.180 N/mm2 Not + Safe air pressure will be minimum of two obtained pressure i.e. 0.135 N/mm2. £8/12.STorsion : Definition : Torque which tend to produce rotation about longitudinal axis is called torsion. eg steering rod, propeller shaft of automobiles ete Indian BOE Exam Guide Book (Edition-1) Author : MITHILESH SINGH, mobile: +91-9827482029, Emall : mithileshkhudawalOgmall.comPART-B[Boil 34 General equation for Torsion Ip R L Where TeTorque Ip=Polar moment of Inertia fs

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