MH BOE 2016 Paper 1 Solution

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MH BOE-2016 Paper-1 (Boiler Engg-1) Solution
website link: http://mithileshkhudawal.wix.com/boeindia

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duration”
Answer :
a – The Latent heat of steam at atmospheric pressure is – 2257 KJ/Kg
b – In case of industrial process heating best quality of steam – dry saturated steam
c – The material used to control the Sox in FBC boiler is – lime stone
d – Which of the fuel has the highest heating value – Hydrogen
e – To regulate and control the flow normally used – globe valve
f – Efficiency = Ox (hg-hf)/q x GCV
= 2000x (660-80)/140x10000 = 82.85 %
g – At critical point, specific volume of water is – 0.00317 m3/kg
h- Discharge pressure of centrifugal BFW pump depends upon – all of above
I – Proper sizing of steam pipe line helps in minimizing – pressure drop
J – The entropy of water at 0 c is – 0
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Question 1B(i) – What is the common form of boiler manhole opening and why?
Answer : Common form of boiler man hole is elliptical shape. The boiler manhole lids
are mounted inside of the boiler so that boiler pressure will help to keep them tight.
Hence manhole have to be elliptical in shape to make it possible to take the lid out from
the boiler.
Question 1B(ii) – What are the reason of water hardness?
Answer : Carbonate or Temporary hardness: Temporary hardness is caused by

presence of dissolved bicarbonate minerals as calcium bicarbonate and magnesium
bicarbonate.
Non carbonate or Permanent hardness: Caused by the presence of salts of calcium
and magnesium but inform of sulphers and chlorides. These precipitate out of solution
due to their reduced solubility as temperature rises, and form hard scale.
Question 1B(iii) – State two causes of rise in flue gas temperature of a boiler.
Answer : 1 – Scale deposit inside the boiler tubes

2 – Soot deposit on the outer surface of the boiler tube.
Question 1B(iv) – How many liters of water at 90*c should be poured in to a tub
containing 120 liters of water at 25*C to get final temperature of mixture at 40 c?
Solution : Suppose “M” liters of water poured into a tube to obtained 40*c of mixture
final temperature.
As per energy balance :
Added water heat+ Containing water heat= Final heat of mixture water
Mx90+120x25=(M+120)x40
90M+3000=40M+4800
90M-40M=4800-3000
50M=1800
M=36 liters (Answer)
Question 1B(v) – A carbon steel pipe has outside diameter of 273 mm and wall
thickness 15 mm. Find weight of 6 meter long pipe in Kg?
Solution : Given Length = 6mtr =600 cm

O.D. of pipe (D) = 273 mm =27.3 cm
Thickness = 15 mm
Inside diameter of the pipe (d) = 273-(2x15) = 243 mm = 24.3 cm
Volume of pipe material = 3/4 x L (D2-d2)
= 3/4 x 600 x {(27.3)2-(24.3)2}
= 72947.78 cm3
Density of material = 7.84 gm/cc
So, Mass of pipe = 7.84 x72947.78
= 571910.5952 gram
= 57.191 KG(Answer)

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Question 2(A) - Write advantage and disadvantage of estimation of boiler
efficiency by direct method.
Answer : Advantage:
1- Plant people can evaluate quickly the efficiency of boiler.
2- Require the few parameter for computation.
3 – Needs few instruments for monitoring.
Disadvantage:
1 – Does not give the clues to operator as to why efficiency of system is lower.
2 – Does not calculate various losses accountable for various efficiency levels.
3 – Evaporation ratio and efficiency may mislead, if the steam is highly wet due to water
carryover.
Question 2(B)– What is objective of boiler water phosphate treatment ? When tri-
sodium phosphate is dissolved in boiler water . What principle reaction takes
place?
Answer : Objective of the boiler water phosphate : To create the condition that will
favor the formation of the sludge instead of scale i.e. scale formers CaSO4,CaSiO3 will
precipitate as loose sludge along with other sludge e.g.CaCO3,3Ca3(PO4)2,Ca(OH2)
which are removed from the boiler unit by blow down. To be more particular, phosphate
treatment is direct to prevent the formation of the calcium scales rather than scales in
general.
Tri-sodium phosphate principal reaction: TSP dissolve in the water to liberate the
phosphate ions ( PO43-) which undergo hydrolysis to render the solution alkaline
PO43- + H2O = HPO42- + OH-
Question 2(C)- Define the terms

(i) Sensible Heat
(ii) Latent Heat
(iii) Critical Pressure
(iv) Dryness fraction
(v) Safe working strength of material
Answer :
Sensible Heat: - It is the amount of heat absorbed by 1kg of water, when heated at a
constant pressure, from the freezing point to the temp. Of formation of steam i.e.
saturation temp. The sensible heat is also known as liquid heat. It is denoted by hf.
Latent Heat: - It is the amount of heat absorbed to evaporate 1 kg of water, at its boiling
point or saturation temperature without change of temp. It is denoted by hfg.
Critical Pressure: -The critical pressure at which density of water and steam becomes
equal at saturation temperature. This is about 225 kgf/cm2 at temperature 374 c .
Dryness fraction: - Known as quality of steam is the ratio of mass of actual dry steam,
to the mass of same quantity of wet steam, and is generally denoted by X.
X= mg/m, mg = mass of actual dry steam, m=mass of wet steam
Safe working strength of material: - Safe working strength of material” means, with
respect to materials handling equipment, the maximum load that the materials handling
equipment is designed and constructed to handle or support safely.

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Question 2(D)- Calculate enthalpy, specific volume, and density of steam at
pressure of 40kg/cm2 absolute and dryness fraction of 0.9?
Solution - From steam table at 40 kg/cm2

hf = 259.72 kcal/kg , hfg = 668.85 kcal/kg
Enthalpy = hf + x hfg
= 259.72 + 0.9(668.85)
= 861.685 kcal / kg
Specific volume = 0.050 m3/kg
Density of steam = 20.101 kg/m3
Question 3(A)- What are the advantages of artificial draught? How boiler furnace
draught can be controlled?
Answer :
Advantage of artificial draught: -
1 – Easy control of combustion and evaporation.
2 – Increase in evaporative power of a boiler.
3 – Improve in efficiency of the plant.
4 – Reduce the chimney height.
5 – Prevention of the smoke.
6 – Low grade can be fuel as intensity of artificial draught is high.
7 – The fuel consumption per H.P. due to artificial draught is 15% less than due to
natural draught.
Boiler furnace draught can be controlled by the balanced draught: The system in which
combustion air is supplied under through the fan and negative draught is created by the
suction of another fan. It is a combination of both Forced draught fan and induced
draught fan.
Question 3(B)-What conditions must be fulfilled for effective operation of the

deaerator?
Answer :
Effective Operation of deaerator: -
1 – The temperature of the dereated water must be equal to saturation temperature of
water corresponding to the pressure at which the dereator operates.
2 – Sufficient heating steam must be delivered to dereator to ensure continuous boiling
of water undergoing deaeration.
3 – The feed water charged to the dereator must be disintegrated into fine droplets to
ensure better heat transfer between heating steam and feed water. Hence perforated
trays find widest application.
4 – The deareator must be provided sufficient venting to purge the non-condensing
gases out of the system and to ensure minimum partial pressure of these gases in the
upper part of the dereator. Reduction of partial pressure will enhance desorption of
dissolved gases.
5 – If two or more dereators are operated in parallel, all must be operated at same
pressure.

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Question 3(C) - In which case boiler must be shut down immediately?
Answer : In following conditions boiler must be shut down immediately :

1- Explosion in the furnace damaging the brickwork or pressure parts
2- Flame extinction in the furnace
3- Deformation of the pressure parts that might invite explosion and endanger the
operating personnel
4- Non permissible of rise of superheated temperature
5- Failure of the feed pump
6- Rupture of the water tubes in the water steam path
7- When there is no steam flow through the steam re-heater
8- When the water level in the drum drops below the safety mark
9- Fuel burning in the heat recovery zone. This is accompanied by abnormal rise of
temperature of the flue gases.
Question 3(D): - The percentage composition by mass of coal sample analysis is

given by C =90%, H2=3.3%, N2=0.8%, S=0.9%, O2=3%, and ash =2%
Calculate
A – Minimum mass of air required for complete combustion of 1kg of coal
B – If 50% excess air is supplied, find mass of dry flue gases per kg of coal
Solution :
A – Minimum or Theoretical air required for complete combustion
= 100/23 {2.67C+8H+S-O}
= 100/23 {2.67x0.9+8x0.033+0.009-0.03}
= 100/23 {2.403+0.264+0.009-0.03}
= 11.50 Kg/Kg of coal
B – If 50% excess air supplied actual air supplied = 1.5x11.50=17.25 kg
Excess Air = 17.25-11.50 = 5.75 kg/kg of coal
For dry product of combustion will consist CO2, SO2, and N2
Wt. of CO2 formed, CO2 = Cx3.67 = 0.9x3.67 = 3.303
SO2 = Sx2 = 0.009x2 = 0.018
Nitrogen will also appear in product of combustion which will be,
N2 = 0.77xair actual supplied = 0.77x17.25=13.2825 kg
Since excess air is supplied, excess oxygen will appear in product of combustion
which will be = 0.23x excess air supplied
= 0.23x 5.75 = 1.3225 kg
Nitrogen in air actual supplied = 13.2825+0.008 = 13.2905 kg
H2O is not considered in dry product of combustion
Now total product of combustion per kg of fuel
CO2 = 3.303 kg
SO2 = 0.018 kg
Oxygen = 1.3225 kg
N2 = 13.2905 kg
Total mass of product of combustion (i.e. flue gas)

= 3.303+0.018+1.3225+13.2905
= 17.934 Kg

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Question 4(A): Differentiate between subcritical and supercritical boiler.
Answer :
Difference between sub critical and supercritical boiler :
Question 4(B): Explain heat transfer by conduction, convection and radiation as

applied to various parts of a water tube high pressure boiler ?
Answer :
Modern high-pressure boilers use the heat transfer by radiation along with conduction
and convection. The total heat-receiving equipment is divided into several parts. So they
can easily be located in various zones of the furnace for most efficient heat transfer to
the water circuit. Boiler is basically a heat exchanger where heat is transferred to water.
It is also sometimes referred to steam generator. Thermal energy for heating water is
supplied either by fuel (Gas, liquid or solid) or by waste energy available from various
industrial processes. Heat energy is transferred by conduction, convection and
radiation. The relative percentage of each is dependent upon the type of boiler, the
designed heat transfer surface and the fuels that power the combustion.
Conduction heat transfer taken place from metal part of the boiler specially tubes of
heating surface area. Convection taking place in to liquid heat transfer from one
molecule to another molecule , whereas radiation heat transfer is taking place in the
combustion part of the boiler where gases travels & heat transferring in radiation mode.

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Question 4(C): - Explain terminology used for “safety valve”- set pressure, blow
down, chattering.
Answer :
Blowdown : Blowdown is the pressure difference between set pressure and pressure at
which the valve reseats expressed as a % of the set pressure.
Blow-down% =[Set pressure-Reset Pressure]x100/Set pressure
Usual range of blowdown % setting of safety valve is 2.5 to 4%.
Set pressure : It is the pressure at which the safety valves starts to open measured at
valve inlet normally 1.1 x working pressure. Higher set pressure lead to invite accident &
lower setting is lead to frequent puffing of safety valve which may hamper process.
Reset Pressure: It is pressure at which safety valve is fully closed. Setting limit within
blowdown range 2.5 to4% is the best safety operating of any system to avoid any
disturbance during normal operation.
Chattering of safety valve : It is the rapid opening and closing of a pressure relief
safety valve. The resulting vibration may cause misalignment valve seat damage and if
prolonged can cause mechanical failure of valve internal and associated piping.
Some cause of chattering include excessive inlet pressure drop excessive back pressure
and over sized relief valve and a relief valve which must handle widely carrying flow
rates. We will explain the under normal process conditions the vessel pressure is below
the set pressure of the relief valve/safety valve and the pressure at the safety valve is
same as vessel pressure, the pressure at the safety valve increases by the same
amount and if the pressure exceeds the relief valve set the pressure valve open.
Question 4(D): - For combustion of 600 litre/hr. of furnace oil, estimate combustion
air quantity required in kg/hr. with 20% excess air. Specific gravity of furnace oil
0.9. (Fuel analysis: C – 84%, H -12%, S – 3%, O – 1%).
Solution: - Given C – 84%,H – 12%,S – 3%,O – 1%

Minimum air required for combustion = 100/23[2.67C+8H+S-O]
= 100/23[2.67x0.84+8x0.12+0.03-0.01]
= 100/23[2.2428+0.96+0.03-0.01]
= 14.012 kg/kg
20% excess air used,
Actual air supplied = 1.2x14.012 = 16.81 kg/kg of oil
Combustion air quantity required = 600x0.9x16.81 = 9077.4 kg/hr(Answer)
Question 5(A): What is the difference between foaming and priming? What are its
causes ?
Answer :
Difference between priming and foaming :
Priming refers to the state of unstable foam formation resulting in the discharge of
steam contained with excessive amount of water droplets because of violent ebullition in
the boiler observed periodically.
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Foaming characterizes stable foam formation i.e. continuous formation of bubbles
possessing sufficiently high surface tension to prevent them from coalescing and
breaking, with the effect that they retain their bubble forms even after their
disengagement from the water surface.
Causes of foaming is due to contamination of boiler water with oil, soap, organic
matter, suspended matter or other foreign particles.
Causes of priming is due to surging (swelling) of water in the steam drum and is
induced by a high water level in the drum. The violent movement of steam bubbles to the
disengagement surface and their explosion causes this swelling and temporarily raises
the water level in the steam drum. The exploding bubbles spray water droplets in the
steam space and these are carried over the steam.
Question 5(B)– What factors contribute to overheating of radiant super-heater?

How overheating can be avoided?
Answer :
Factors contribute to overheating of radiant super-heater :
1 – Vulnerability during start up.
2 – Deposition of scale on the steam side of super heater coil impairing heat transfer.
3 – Flame impingement directly upon the super-heater coils.
Overheating can be avoided by

1 – Burner adjustment
2 – Tilting the burner
3 – Proper flame control
4 – Increasing distance between the burner and radiant super-heater surface
5 – The scale formation on the steam side can be prevented by enhance steam
purification before it is charged to the super-heater.
Question 5(C)–Describe various types of steam condensers. What are various

causes for poor performance of condensers and what are the remedies for
improvement in performance?
Answer:
Various type of condensers :
1 – Jet condenser
a – Parallel flow type
b – Contra flow type
c – Ejector type
2 – Surface condenser
a – Down flow type
b – Central flow type
c – Inverted flow type
d – Evaporative type

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Question 5(D)–Following are the particulars refer to a steam plant consisting of

boiler, economizer, and a super-heater: -
Steam pressure = 14 bar absolute,
Mass of steam generated = 5000 kg/hr,
Calorific value of coal = 29800 kj/kg,
Temperature of feed water entering the economizer = 30*c,
Temperature of feed water leaving the economizer = 130*c,
Dryness fraction of steam leaving the boiler drum = 0.97
Temperature of steam leaving the super heater = 320*c
Calculate
1 Overall efficiency of the plant
2 The percentage of heat utilized in boiler, economizer, and super heater.
Solution: - From steam table at 14 bar absolute pressure

hf = 830.30 , hfg 1959.69 , Ts = 195 c
Enthalpy of 1 kg of wet steam at 14 bar & 0.97 dryness fraction
Hwet = hf + x hfg
= 830.3+0.97(1959.69) = 2731.11 KJ/KJ = 653.37 Kcal/kg
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Enthalpy of 1 kg of SH steam at 14 bar & 320 c
Hsup = hf + hfg + kp( tsup-ts )
= 830.3+1956.69+ 2.30(320-195) Sp. Heat of super-heated steam = 2.30 kj/kg]
= 2914.99 Kj/Kg = 697.37 Kcal / kg
Overall efficiency of the plant = Heat output/Heat input

= 5000x (697.37-30)/675x7129.18
= 69.34%
Heat gain by feed water in economizer = MxsxΔt = 5000x1x (130-30) = 500000 kcal
% Heat absorption in economizer = 500000/Heat out put
= (500000/3336850) x100
= 14.98 %
In boiler = m [ hsatr-hfout]
= 5000x [{198.63+0.97x468.83}-130]
= 2616975.50 kcal
% Heat absorption in boiler = (2616975.50 /3336850) x100
= 78.42%
In super heater = m x [ hsup-hsat]

= 5000 x [697.37-653.39]
= 219900 kcal
% Heat absorption in superheater
= (219900/3336850) x100
= 6.59 %
Question 6 : Write short note on :

(i) Boiler Log book importance and its contents
(ii) Sugar test to the boiler water
(iii) Fuel storage hazards and prevents measure of bagasse.
(iv) Balanced draught system
(v) Membrane type water wall
Answer:
Boiler Log book importance and its contents : If a boiler is to be kept in good
operating condition, someone who tends to the boiler must be responsible for its
operation and maintenance. This person should have a good understanding of boiler
operation and safety devices. Maintenance and testing should be performed and
recorded in the log on a routine basis. The responsible individual should initial the log to
verify each operation performed, who performed it, and when it was performed.
Properly maintained engineer log books can reduce the number of boiler room
accidents. Engineer log books are a checklist for boiler room operators, engineers, and
managers. A key factor in any boiler room is the preventative maintenance performed on
the boiler on a daily basis. This helps to avoid any emergency shut downs or costly
accidents. By maintaining the log on a daily basis, the operator can properly diagnose
problems and set up a suitable maintenance schedule. Control failure and maintenance
mistakes make up a majority of the boiler room accidents that occur. Properly kept boiler
logs help operators avoid operational and maintenance errors and can greatly reduce
the number of accidents
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Sugar test to the boiler water : At most sugar factories where condensates are used
as boiler feed water, this liquid is regularly analysed for the presence of sugar. Not only
because its presence indicates an increase in undetermined losses, but more so
because of its detrimental effect on. The boilers. In the alkalized feed water, sugar tends
to decompose into sugar acids and other products which lower the pH and in this way
increase the rate of corrosion of boiler tubes. In addition, the boiler water has a tendency
to foam, which results in a carryover of salts in the steam. The presence of sugar in
condensate is often not continuous, but occurs for short periods only, at irregular
intervals. For this reason, the testing of feed water must be carried out very frequently if
it is to be effective, and a continuous automatic analyser would therefore provide a much
better means of control than analysis carried out intermittently.
Fuel storage hazards and prevents measure of bagasse : The bulk storage of
bagasse can cause impact on nearby water ways. If contaminated storm water, leachate
and wind borne bagasse enters a water way it has the potential to reduce dissolved
oxygen and extreme circumstances this can result in fish kills.
Precaution
1- Stock pile bagasse in location with effective storm water management system.
2- Stock piles the bagasse on pad with a permeability of not more than 9m/sec,
3- Provide an extra area of compacted pad to manage bagasse that has developed
high temperature.
Balanced Draft: Forced-draft (F-D) fan (blower) pushes air into the furnace and an
induced-draft (I-D) fan draws gases into the chimney thereby providing draft to remove
the gases from the boiler. Here the pressure is maintained between 0.05 to 0.10 in. of
water gauge below atmospheric pressure in the case of boilers and slightly positive for
reheating and heat treatment furnaces.
Membrane type water wall : The membrane water wall is now common. It consist of
tubes spaced on centers having center to center distance varying from 1.2 to 1.3 times
the tube diameter. The tubes are connected by bars or membranes welded to them at
their center line. The membrane act as fins to increase the heat transfer as well as to
strengthen the furnace construction. Insulation is provided on the outer side of the wall,
and then a metal lagging is giving to protect the insulation. The tube diameter varies
from 68 to 76.2 mm.

duration”

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Indian BOE Coaching Services

MH BOE-2016 Paper-1 (Boiler Engg-1) Solution

website link: http://mithileshkhudawal.wix.com/boeindia

Question 1B(ii) – What are the reason of water hardness?

Answer : Carbonate or Temporary hardness: Temporary hardness is caused by

Answer : 1 – Scale deposit inside the boiler tubes

Solution : Given Length = 6mtr =600 cm

website link: http://mithileshkhudawal.wix.com/boeindia

Question 2(C)- Define the terms

website link: http://mithileshkhudawal.wix.com/boeindia

Solution - From steam table at 40 kg/cm2

Question 3(B)-What conditions must be fulfilled for effective operation of the

website link: http://mithileshkhudawal.wix.com/boeindia

Answer : In following conditions boiler must be shut down immediately :

Question 3(D): - The percentage composition by mass of coal sample analysis is

Total mass of product of combustion (i.e. flue gas)

website link: http://mithileshkhudawal.wix.com/boeindia

Question 4(B): Explain heat transfer by conduction, convection and radiation as

website link: http://mithileshkhudawal.wix.com/boeindia

Solution: - Given C – 84%,H – 12%,S – 3%,O – 1%

Question 5(B)– What factors contribute to overheating of radiant super-heater?

Overheating can be avoided by

Question 5(C)–Describe various types of steam condensers. What are various

website link: http://mithileshkhudawal.wix.com/boeindia

Question 5(D)–Following are the particulars refer to a steam plant consisting of

Solution: - From steam table at 14 bar absolute pressure

Overall efficiency of the plant = Heat output/Heat input

In super heater = m x [ hsup-hsat]

Question 6 : Write short note on :

website link: http://mithileshkhudawal.wix.com/boeindia

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