Paper 2 – Set B Key

Regn No: _________________

Name: ___________________
(To be written by the candidates)

7th NATIONAL CERTIFICATION EXAMINATION – Nov. 2008

FOR
ENERGY MANAGERS & ENERGY AUDITORS

PAPER – 2: Energy Efficiency in Thermal Utilities

Date: 22.11.2008 Timings: 1400-1700 HRS Duration: 3 HRS Max. Marks: 150

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Section - II: SHORT DESCRIPTIVE QUESTIONS Marks: 8 x 5 = 50

(i) Answer all Eight questions

(ii) Each question carries Five marks

S-1 What are the advantages & disadvantages of calculating Boiler efficiency by
direct method? Calculate the boiler efficiency if the evaporation ratio is 6 for a
coal fired boiler? Steam enthalpy – 650 kcal/kg & GCV of coal – 5000 kcal/kg,
feed water temperature 40oC

Answer:

a) Advantages of Direct Method - Simple & Easy to calculate

Disadvantages - It does not indicate which loss is predominant

b) Evaporation Ratio = 6
Boiler Efficiency = Evap. Ratio ( Steam Enthalpy – F.Water enthalpy) x 100
------------------------------------------------------------------
GCV of fuel
= 6 (( 650 – 40)/(5000)) * 100
= 73.2%

S-2 Match the following:

Cogeneration system Typical range of heat to power ratio

a) Back pressure steam turbine 1) 2.0 – 10.0

b) Extraction-condensing steam turbine 2) 1.3 – 2.0
c) Gas turbine 3) 1.1 – 2.5
d) Combined cycle 4) 1.0 – 1.7
e) Reciprocating engine 5) 4.0-14.3

Answer:

a – 5, b – 1, c – 2, d – 4, e - 3

S-3 In a re-rolling mill furnace the outlet flue gas temperature is 550oC. The
industry has installed a recuperator to preheat combustion air upto 300oC and
reduces fuel consumption by 15%. List down other three more advantages other
than reduction in fuel consumption which would accrue to the industry.

Answer:
• Reduction in scale losses
• Yield Improvement
• Higher throughput from the furnace
• Any other relevant point !!!!

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S-4 List five disadvantages if the steam pipe line is not insulated:

Answer:

Heat Loss from bare surfaces

Steam condensation in pipes
Water Hammering
Poor quality of steam to process
Leakage through the flanges and valves due to vibration caused by water
hammering effect
Any other relevant point !!!!

S-5 The data of gas turbine of gas based power plant is given below. Calculate the
efficiency of gas turbine.
Capacity of gas turbine = 0.220 GW
Plant operating hours per Annum = 8000 hrs
Plant load factor = 90 %
Gas Consumption per Annum = 526 MMSCM
Calorific value of gas = 8400 Kcal/SCM

Answer:

Efficiency of Gas Turbine =

= Power Generation in KWh X 860 Kcal/KWh x 100

Avg. Gas Consumption/month in SCM x NCV in Kcal/SCM

Annual power generation = 0.220 x 10^6 x 8000 x 0.9

= 1584 x 10^6 KWh

Efficiency = (1584 x 10^6 x 860) x 100 = 30.83%

(526 x 10^6 x 8400)

S-6 List three methods by which steam trap performance is assessed

Answer:
• Visual testing
• Sound Testing
• Temperature Testing

S-7 Calculate the savings in heat loss due to reduction in blow down by using auto
blow-down controller, from 2.5% to 1% for 10T/hr boiler, which operates 8000
hrs/year. The temperature of boiler blow down water is 180oC, boiler
efficiency is 80% and GCV of F.oil is 10,000 kCal/kg. Feed water temp.= 30oC

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Answer:

Present blow –down quantity = 10 x (2.5/100) = 0.25 Ton/hr

Blow down quantity with controller = 10(1/100) = 0.1 Ton/hr
Reduction in Blow down = 0.25 – 0.1 = 0.15 ton/hr

Heat savings = 0.15 x 1000 x (180-30) = 22500 Kcal/hr

Equivalent F.oil savings = 22500/(10000*0.8) = 2.81 Kg/hr
Annual F.oil Savings = 2.81 x 8000 = 22500 kg or 22.5 T/yr

S-8 For combustion of 125 m3/hr Methane gas, estimate quantity of air
required with 10% excess air. Density of methane gas is 0.6 kg/m3

Answer:

CH4 + 2O2 -------------Æ CO2 + 2H2O

16 64

For 16 kg of Methane require 64 kg of Oxygen or (64/0.23) 278 kg of air

125 m3/hr methane = 125 x 0.6 = 75 kg of Methane
So, 75 kg of methane require = (75/16) x 278 = 1303.125 kg/hr of Stochiometric
air .

With 10% excess air the Actual air required = (1+(10/100)) * 1303.125
= 1433.43 kg/hr

-------- End of Section - II ---------

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Section - III: LONG DESCRIPTIVE QUESTIONS Marks: 6 x 10 = 60

(i) Answer all Six questions

(ii) Each question carries Ten marks

L-1 An oil fired boiler has the following operating parameters

Steam Generation = 5 T/hr

Steam Pressure = 8 kg/cm2
Feed water temperature = 60 oC
Steam Enthalpy = 660 kcal/kg
Saturation temperature = 170 oC
Boiler efficiency = 80%
GCV of Oil = 10,000kCal/kg
Steam Quality = Dry Saturated

a) Calculate fuel oil consumption per hour

b) If the dryness fraction becomes 0.7, calculate fuel oil consumption per hour
assuming same boiler efficiency

Answer:
a)
Boiler efficiency = Q X (hs - hf) X 100 / q x GCV of oil

80 = 5000 x (660 – 60) x 100 / q x 10,000

q = 375 kg/hr

b)
80 = [3500 x (660 – 60) + 1500 (170 – 60)] x 100 / q x 10,000
q = 283.12 kg/hr

L-2 Explain the significance of heat to power ratio. Under what circumstances is
cogeneration attractive?

Answer:

Heat to power ratio is one of the most technical parameters influencing the selection of
the type of cogeneration system. The heat to power ratio of the facility should match with
the characteristics of the cogeneration system to be installed.I t is defined as the ratio of
thermal energy to the electricity required and expressed as kWth/kWe.The plant may
therefore be setup to supply part or all of the site heat and electricity loads or an excess
of either may be exported if a suitable customer is available.

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Cogeneration is most attractive under following conditions:

¾ Demand for steam and power is balanced.
¾ Peaks and troughs in demand can be managed.
The ratio of heat to power required by a site may vary during different times of the day
and seasons of the year. Importing power from grid can makeup shortfall in electrical
output from cogeneration plant and firing standby boilers can satisfy additional heat
demand. Many large cogeneration units utilize supplementary firing of exhaust gases in
order to modify the heat to power ratio of the system to match site loads.

L-3 An uninsulated 100 mm pipe of 200m length carries steam at 10 kg/cm2. The
surface temperature measured is 1650C. Find out the annual cost saving achieved by
insulating it with 50 mm. insulating material, which will bring the surface temperature
down to 600C. The boiler efficiency is 85%,the fuel oil (with GCV of 10000 Kcal/kg)
cost is Rs.20,000 / tonne and ambient air temperature is 300C and annual operating
hour is 8000 hours.

Answer:

Ts = 1650C
Ta = 300C
Existing heat loss (By formulae) = 2261.25 kCal/hr.m2

Heat loss in modified system (S2) (By formulae) = 345 kCal/hr.m2

Existing pipe dimension = Ø 100 mm & 200 m length

Existing surface area (A1) = 3.14 x 0.1 x 200 = 62.8 m2

Surface area after insulation = 3.14 x 0.2 x 200 = 125.6m2

Total heat loss in existing system = 62.8 x 2261.25 = 142006.5 Kcal/hr.

Total heat loss in modified system = 125.6 x 345 = 43332 Kcal/hr

Reduction in heat loss = 142006.5 – 43332 = 98674.5 Kcal/hr.

Total annual heat loss = 98674.5 x 8000
= 7893.96 x 105 Kcal
Calorific value of fuel = 10000 Kcal/ kg
Boiler Efficiency = 85%
Annual fuel oil saving = 7893.9 x 105 /1000 x 0.8
= 92869 kg/year
Annual cost saving = 92869 x 20000/1000

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Annual cost saving = Rs.18,57,380/-

L-4 (a) Explain the important properties of ceramic fibre.

(b) Name five general requirements of refractory material.

Answer:

¾ Lower Thermal Conductivity: This allows construction of thinner linings.

¾ Lower Heat Storage : Less heat absorption due to lower density.
¾ Good thermal shock resistance: Allows faster heating and cooling.
¾ Mechanical Resilience: This allows prefabrication.
¾ Low installation Cost.
¾ Simple Maintenance.
¾ Higher Thermal Efficiency: Allows more accurate and uniform temperature.

The general requirements of a refractory material can be summed up as :

• Ability to withstand high temperatures.

• Ability to withstand sudden changes of temperatures.
• Ability to withstand action of molten metal slag, glass, hot gases, etc.
• Ability to withstand load at service conditions.
• Ability to withstand load and abrasive forces.
• Low coefficient of thermal expansion.
• Should be able to conserve heat.
• Should not contaminate the material with which it comes into contact.

L-5 (a) Calculate the blow down rate for a boiler with an evaporation rate of 4 tons/hr, if
the maximum permissible TDS in boiler water is 3500 ppm and with 20 % make
up water addition. The feed water TDS is around 350 ppm.
(b) Steam at a pressure of 15 kg/cm2g is flashed to a lower pressure of 2 kg/cm2g. If
the steam flow rate is 2000 kg/hr. Calculate the % of flash steam and flow rate of
flash steam?

Given are the data from steam tables :

Sensible heat of steam at 15 kg/cm2g : 200 kCal/kg
Sensible heat of steam at 2 kg/cm2g : 120 kCal/kg
Latent heat of steam at 2 kg/cm2g : 526 kCal/kg

Answer:

a) Blow down (%) = Feed water TDS x % Makeup/ Permissible TDS in Boiler

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Percentage blow down = 350 x 20/3500 = 1.99 %

If boiler evaporation rate is 4000 kg/hr then required blow down rate is:
= 4000 x 1.99 / 100 = 79.6 kg /hr

b) The flash steam quantity can be calculated from the following formula:
% Flash steam = S1 –S2/ L2
Where S1 is the sensible heat of high pressure condensate.
S2 is the sensible heat of steam at lower pressure
L2 is the latent heat of flash steam at the lower pressure.

Substituting values= (200-120)/526 =80/526 =15.2%

Flow rate of high-pressure steam: 2000 kg/hr.
Flash steam quantity: 2000*(15.2/100) = 304 kg/hr.

L-6 List ten energy conservation opportunities available in a boiler system

Answer :

Stack Temperature
Feed water preheating using economizer
Excess air control
Combustion air pre heating
Automatic Blowdown
Reduction of scaling and soot losses
Radiation and convection heat loss
Variable speed control for blowers and pumps
Proper boiler loading
Incomplete combustion and unburnt losses

-------- End of Section - III ---------

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