(1) Heat Pump

The majority of heat pumps work on the principle of the vapour compression cycle. In this cycle, the circulating
substance is physically separated from the source (waste heat, with a temperature of T in) and user (heat to be
used in the process, Tout) streams, and is re-used in a cyclical fashion, therefore called 'closed cycle'. In the
heat pump, the following processes take place:
a) In the evaporator the heat is extracted from the heat source to boil the circulating substance;

b) The circulating substance is compressed by the compressor, raising its pressure and temperature; The
low temperature vapor is compressed by a compressor, which requires external work. The work done on
the vapor raises its pressure and temperature to a level where its energy becomes available for use
c) The heat is delivered to the condenser;
d) The pressure of the circulating substance (working fluid) is reduced back to the evaporator condition in
the throttling valve, where the cycle repeats.
The heat pump was developed as a space heating system where low temperature energy from the ambient air,
water or earth is raised to heating system temperatures by doing compression work with an electric motor
driven compressor

(OR)

(2) Thermocompressor :
In many cases, very low pressure steam are reused as water after condensation for lack of any better option of reuse.
In many cases it becomes feasible to compress this low pressure steam by very high pressure steam and reuse it as a
medium pressure steam. The major energy in steam, is in its latent heat value and thus thermocompressing would
give a large improvement in waste heat recovery.
The thermocompressor is a simple equipment with a nozzle where HP steam is accelerated into a high velocity fluid. This
entrains the LP steam by momentum transfer and then recompresses in a divergent venturi. A figure of
thermocompressor is shown in Figure.
It is typically used in evaporators where the boiling steam is recompressed and used as heating steam.
 Thermocompressor

Functions of Steam Traps

The three important functions of steam traps are:

 To discharge condensate as soon as it is formed

 Not to allow steam to escape
 To be capable of discharging air and other incondensible gases

Working principle of thermodynamic trap

The thermodynamic trap operates by means of the dynamic effect of flash steam as it passes through the trap. The only
moving part is the disc above the flat face inside the control chamber or cap.

On start-up, incoming pressure raises the disc, and cool condensate plus air is immediately discharged from the inner
ring, under the disc, and out through three peripheral outlets.

Hot condensate flowing through the inlet passage into the chamber under the disc drops in pressure and releases flash
steam moving at high velocity. This high velocity creates a low pressure area under the disc, drawing it towards its seat.
At the same time, the flash steam pressure builds up inside the chamber above the disc, forcing it down against the
incoming condensate until it seats on the inner and outer rings. At this point, the flash steam is trapped in the upper
chamber, and the pressure above the disc equals the pressure being applied to the underside of the disc from the inner
ring. However, the top of the disc is subject to a greater force than the underside, as it has a greater surface area.

Eventually the trapped pressure in the upper chamber falls as the flash steam condenses. The disc is raised by the now
higher condensate pressure and the cycle repeats

a) Dryness fraction of steam

Dryness fraction is defined as mass of dry steam in one kg of mixture of dry steam and water vapour.

(or)

The total heat of dry saturated steam or enthalpy of saturated steam is given by sum of the two enthalpies hf
+hfg. When the steam contains moisture the total heat of steam will be hg = hf + hfg where is the dryness
fraction. Here is fraction.

b) Net calorific value

The calorific value is the measurement of heat or energy produced. Net calorific value (NCV) assumes the
water leaves with the combustion products without fully being condensed.

c) Emissivity coatings
high emissivity coatings allows the surface emissivity of materials to be increased, with resultant benefits in heat
transfer efficiency and in the service life of heat transfer components. High emissivity coatings are applied in the
interior surface of furnaces. High emissivity coating shows a constant value of emisivity over varying process
temperatures.
The application of high-emissivity coatings in furnace chambers promotes rapid and efficient transfer of heat, uniform
heating, and extended life of Refractories and metallic components such as radiant tubes and heating elements. For
intermittent furnaces or where rapid heating is required, use of such coatings was found to reduce fuel or power to
tune of 25-45%. Other benefits are temperature uniformity and increased refractory life

d) Turndown ratio
Turndown ratio is an important aspect to be considered in selection of burner. Turndown ratio is the
relationship between the maximum and minimum fuel input without affecting the excess air level
Write short notes on economic insulation thickness for energy efficiency.

Ans: Insulation of any system means capital expenditure. Hence an important factor in any insulation system is to
analyse the thermal insulation with respect to cost. The effectiveness of insulation follows the law of decreasing returns.
Hence, there is a definite economic limit to the insulation thickness, which is justified. Excess thickness is uneconomical
and cannot be recovered through heat savings. Each industry has different cost of heat loss due to variation in fuel cost
and boiler efficiency. These values can be used for calculating economic thickness of insulation, where thickness for a
given set of circumstances, which results in the lowest overall cost of insulation and heat loss combined economic
insulation thickness
Mechanical trap Principle of operation is difference in density between steam and condensate The different
mechanical traps are
Open bucket (or)
Inverted bucket (or)
Float type

3 Marks Thermodynamic trap Principle of operation is difference in thermodynamic properties between

steam and condensate The different thermodynamic traps are
Disc type

4 Marks Thermostatic trap Principle of operation is difference in temperature between steam and
condensate. The different thermostatic traps are
Bimetallic type

What is the need for boiler blow down? Explain intermittent and continuous blow down. Ans: Water contains certain
percentage of dissolved solids. The percentage of dissolved solids found in boiler water depend on the untreated feed
water quality, the treatment process and the boiler operating procedures, as the feed water evaporate in to steam,
dissolved solids concentrate in the boiler either in dissolved or suspended state. Above certain level of concentration,
these solids encourage foaming and cause carry over of water in to the steam. This leads to scale formation inside the
boiler, resulting in localized overheating and ending finally in tube failure. If in therefore necessary to control the level of
concentration of the solids and this is achieved by the process of blowing down, where a certain volume of water in
blown off and is automatically replaced by feed water – thus maintaining the optimum level of total dissolved solids
(TDS)in the water . 4 Marks The intermittent blow down in given by manually operating a valve fitted to discharge pipe
at the lowest point of boiler shell to reduce parameters with in prescribed limits so that steam quality is not likely to be
affected. 3 Marks The continuous blow down is a steady and constant dispatch of small stream of concentrated boiler
water and replacement by steady and constant inflow of feed water. This ensures constant TDS and steam purity at a
given steam load .once blow down valve is set for a given conditions there is no need for regular operator intervention.

Briefly explain the working of a thermic fluid heater and its advantages over steam heating system

Ans In thermic fluid heaters, a specific type of oil synthetic/mineral is used as heat carrier. This fluid can be
heated upto 300oC at atmospheric pressure. In comparison steam would require a pressure of 85 bars to
obtain this temperature. The heaters are made with coils of seamless tubes. The thermal fluid is heated during
the flow through the tubes. The heat is transferred to the fluid as radiant heat in the combustion chamber,
where the inner cylindrical tube coil and a flat tube coil form the chamber wall and the bottom respectively. The
hot thermic fluid is circulated to various process equipments such as dryers, heaters, deodouriser etc. where it
gives up the heat. The return oil at a temperature 10 to 20 0C less comes back to the thermic fluid heater to get
heated up again. The circulation is carried out by a thermic fluid circulation pump. The thermic fluid heater
operates between two temperature ranges. Once the upper limit is reached the burner is switched OFF or goes
into the low fire mode. In the case of solid fuel fired system the ID fan switches OFF on reaching the upper
limit. When the temperature reaches the lower limit due to heat transfer in the process, the burners come ON
again and in case of solid fuels, the ID fan comes ON again. There are several advantages in using thermic
fluids compared to steam systems. The most obvious advantages are as follows
High temperature operation at atmospheric pressure

Optional temperature level set points

No supply of treated water and hence no heat loss due to condensate flash steam
No risk of corrosion
Easy to operate

List down five energy conservation measures in steam system Ans:

Fix steam leaks and condensate leaks.
Use back pressure steam turbines to produce lower steam pressures.
Use dry steam for indirect process heating.
Ensure process temperatures are correctly controlled.
Maintain lowest acceptable process steam pressures.
Remove or blank off all redundant steam piping.
Ensure condensate is returned or re-used in the process.
Preheat boiler feed-water.
Recover boiler blowdown.
Check operation of steam traps.
Remove air from indirect steam using equipment
Inspect steam traps regularly and repair malfunctioning traps promptly.
Consider recovery of flash steam
Use waste steam for water heating.
Reduce work done by steam
ANY OTHER RELEVANT POINT
What is meant by trigeneration? Explain how trigeneration can be applied in a hotel using DG set continuously for
power generation.

Ans: Trigeneration refers to simultaneous generation of steam (heat), power and refrigeration through integrated
systems. Industries requiring electricity, steam and cooling such as food processing and cold storages find the concepts
of tri-generation very attractive. In a Hotel, power can be generated from DG sets and with the waste heat, steam can be
generated. This steam can be used for both Vapour absorption system for generating chiller water for AC applications
and also for generating hot water .

Briefly explain the significance of LMTD in a heat exchanger

The driving force for any heat transfer process is the temperature difference between two fluids. In the heat transfer
process, the temperature of the two fluids keep changing as they pass through the heat exchange, for which some types
of average temperature is needed. The average temperature difference through the heat exchange is described by the
log mean temperature difference (LMTD). The larger the temperature difference, the smaller the required heat
exchange area and vice versa

Wet preservation method for boilers: In the wet method the boiler is filled to the normal level with water at a
pH of 10.5 to 11. Hydrazine to the extent of 200 ppm is to be dosed with the water. The unit is to be steamed in
service to ensure uniform concentration of boiler water throughout the unit and to eliminate dissolved oxygen
from water. Sodium sulphite (Na2SO3), which acts as a de-oxygenerator, can also be used as an alternative to
hydrazine and the sulphite concentration has to be maintained at 300-400 ppm. Analysis of boiler water should
be carried out frequently. If the hydrazine concentration in water happens to drop below 50 ppm, the water in
the drum should be lowered to the normal operating level and an appropriate quantity of chemicals should be
dosed to bring back 200 the concentration of hydrazine or sodium sulphite. The boiler should be steamed to
circulate chemicals to uniform concentration.

b) Reverse osmosis: When solutions of differing concentrations are separated by a semi-permeable

membrane, water from less concentrated solution passes through the membrane to dilute the liquid of high
concentration, which is called osmosis. If the solution of high concentration is pressurized, the process is
reversed and the water from

the solution of high concentration flows to the weaker solution. This is known as reverse osmosis. c) Reciprocating
engine co-generation system: Also known as internal combustion (I. C.) engines, these cogeneration systems have high
power generation efficiencies in comparison with other prime movers. There are two sources of heat for recovery:
exhaust gas at high temperature and engine jacket cooling water system at low temperature. As heat recovery can be
quite efficient for smaller systems, these systems are more popular with smaller energy consuming facilities, particularly
those having a greater need for electricity than thermal energy and where the quality of heat required is not high, e.g.
low pressure steam or hot water
Hot Blast Cupola The temperature of exhaust gas of a cupola is as high as 800 °C, making it possible to preheat
blast air up to as high as 400 °C by heat exchange. In addition, both the sensible and latent heat of exhaust gas can
be recycled for preheating blast air by combustion of CO gas included in exhaust gas. When blast air is preheated to
300 °C or higher, the sensible heat of blast air is added to heat input, activating combustion of coke, leading to the
rise in combustion temperature

‘Steam should be used in the process at the lowest acceptable pressure’ . Explain
the significance of the terms ‘lowest’ and ‘acceptable’

‘lowest’ : Lower the pressure higher is the latent heat which is primarily used in the
process. Hence the lowest pressure would be desirable.
‘acceptable’: However the lower the steam pressure lower will be the steam
temperature. Since the temperature is the driving force for heat transfer, rate of heat
transfer reduces and increases process time. Therefore there is a limit to the reduction
in steam pressure.

Explain briefly about ‘turbine heat rate’. How is it related to turbine efficiency

Heat rate is the heat input to turbine, needed to produce 1 kWh of electricity
Turbine efficiency is the ratio useful heat and power output, to the heat input to the
turbine in Kcal or KJ, expressed as a percentage. Performance of steam turbine is
also expressed as heat rate, which is the quantity of heat in kCal or KJ required to
generate 1 kWh of electrical power output.
Turbine heat rate is expressed in kJ/kWh. The inverse relation between heat rate and
efficiency is applicable only to a power plant, since all the input energy is deployed
for power generation alone.

Explain any two proven methods of testing steam traps?

There are two proven methods of testing of steam traps: - Sound method and
Temperature method.
1.Sound Method : Mechanisms within steam traps and the flow of steam and
condensate through steam traps generate sonic (audible to the human ear) and
supersonic sounds. Proper listening equipment, coupled with the knowledge of
normal and abnormal sounds, can yield reliable assessments of steam trap working
condition. Listening devices range from a screwdriver or simple mechanic's
stethoscope that allow listening to sonic sounds.
2.Temperature Method: Saturated steam and condensate exist at the same
temperature. So it's not possible to distinguish between the two based on temperature.
Still, temperature measurement provides important information for evaluation
purposes.
A cold trap (i.e., one that is significantly cooler than the expected saturated steam
temperature) indicates that the trap is flooded with condensate, assuming the trap is in
service. On the other hand, the temperature downstream of the trap will be nearly
constant if significant steam is getting past the trap. At the low-end, spitting on the
trap and watching the sizzle provides a general indication of temperature.
Finally, non-contact (i.e., infrared) temperature measuring devices provide the
precision of thermometers and thermocouples without requiring physical contact.
Non-contact temperature measurement makes it easier to evaluate traps that are
relatively difficult or dangerous to access closely.

Shell-and-tube heat exchangers consist of a bundle of parallel tubes that provide the heat-transfer
surface separating the two fluid streams. The tube-side fluid passes axially through the inside of
the tubes; the shell-side fluid passes over the outside of the tubes. Baffles external and
perpendicular to the tubes direct the flow across the tubes and provide tube support.
Tube sheets seal the ends of the tubes, ensuring separation of the two streams. The process fluid
is usually placed inside the tubes for ease of cleaning or to take advantage of the higher pressure
capability inside the tubes. The thermal performance of such an exchanger usually surpasses a coil
type but is less than a plate type. Pressure capability of shell-and-tube exchangers is generally
higher than a plate type but lower than a coil type.

Plate Heat Exchangers

Plate heat exchangers consist of a stack of parallel thin plates that lie between heavy end plates.
Each fluid stream passes alternately between adjoining plates in the stack, exchanging heat
through the plates. The plates are corrugated for strength and to enhance heat transfer by directing
the flow and increasing turbulence. These exchangers have high heat-transfer coefficients and
area, the pressure drop is also typically low, and they often provide very high effectiveness.
However, they have relatively low pressure capability.
The biggest advantage of the plate and frame heat exchanger, and a situation where it is most
often used, is when the heat transfer application calls for the cold side fluid to exit the exchanger at
a temperature significantly higher than the hot side fluid exit temperature i.e. “temperature
cross”. This would require several shell and tube exchangers in series due to the lack of purely
counter-current flow.
The overall heat transfer coefficient of plate heat exchangers under favorable circumstances can
be as high as 8,000 W/m2 oC. With traditional shell and tube heat exchangers, the U-value will be
below 2,500 W/m2 oC.

a) Natural gas requires less amount of excess air compared to solid/liquid fuels
Natural gas is in the gaseous form and lighter than air, it mixes with air readily (intimate mixing of
air (oxygen) and fuel takes place) and aids to complete combustion with less amount of excess air.
It does not produce smoke or soot. It has no sulphur content. It is lighter than air and disperses into
air easily in case of leak. Natural gas is also free of ash.
Solid or liquid fuels must be changed to a gaseous form before they will burn. Hence it requires
more excess air compared to natural gas for complete combustion. Solid fuels need to be
pulverized properly to get uniform sizes and liquid fuels need to be preheated and atomized

properly for intimate mixing with air to ensure complete combustion. Hence more excess air is
provided for solid and liquid fuels.
b) Steam is to be used at the lowest practicable pressure for indirect process heating
A study of the steam tables would indicate that the latent heat in steam reduces as the steam
pressure increases. It is only the latent heat of steam, which takes part in the heating process
when applied to an indirect heating system. Thus, it is important that its value be kept as high as
possible. This can only be achieved if we go in for lower steam pressures. As a guide, the steam
should always be generated and distributed at the highest possible pressure, but utilized at as low
a pressure as possible since it then has higher latent heat.
However, it may also be seen from the steam tables that the lower the steam pressure, the lower
will be its temperature. Since temperature is the driving force for the transfer of heat at lower steam
pressures, the rate of heat transfer will be slower and the processing time greater. In equipment
where fixed losses are high (e.g. big drying cylinders), there may even be an increase in steam
consumption at lower pressures due to increased processing time. There are, however, several
equipment in certain industries where one can profitably go in for lower pressures and realize
economy in steam consumption without materially affecting production time.
Therefore, there is a limit to the reduction of steam pressure. Depending on the equipment design,
the lowest possible steam pressure with which the equipment can work should be selected without
sacrificing either on production time or on steam consumption
Arrange the following fuels in decreasing order of their GCV’s - (p) Bagasse, (q) Furnace Oil, (r) Coal,
(s) Hydrogen
a) s-q-r-p
 Water logging of 3 m lift of condensate, at trap discharge, will result in back pressure of _________
a) 0.03 kg/cm2 b) 0.3 kg/cm2
c) 3 kg/cm2 d) 30 kg/cm2
When pure hydrogen is burnt with stoichiometric air,
6. percentage CO2 on volume basis, in dry flue gas, will
be _____
a) 79% b) 21%
c) 0% d) 100%

The viscosity of furnace oil will be maximum at which of the following temperatures?
a) 40 oC

Thermo-compressor is commonly used for :

a) compressing hot air b) upgrading low pressure steam

Which type of the following co-generation system has high heat-to-power ratio?
a) gas turbine b) back pressure turbine

Capillary wick is a part of:

c) heat pipe d) regenerator
Scale losses in reheating furnaces will:
16. a) increase with CO in
combustion gases b) increase
with excess air

Turn down ratio of a burner is the ratio of

a) maximum to minimum fuel input without affecting optimum excess air levels

Dolomite is a ________ type of refractory:

b) a) acidic b) basic

The cogeneration system which has high overall system efficiency is :

a) back pressure steam turbine

Reduction of steam pressure, in a process heating application will :

a) reduce the steam temperature b) reduce the sensible heat
c) increase the enthalpy of evaporation d) all of the above

The measured O2 in flue gas is 5.5 % by volume, the excess air percentage will be
a) 41 % b) 55.9 %
c) 35.5 %

The measured O2 in flue gas is 5.5 % by volume, the excess air percentage will be
a) 41 % b) 55.9 %
c) 35.5 %

The measured O2 in flue gas is 5.5 % by volume, the excess air percentage will be
a) 41 % b) 55.9 %
c) 35.5 %

In reheating furnace, scale losses will

a) Increase with excess air
Which of the following increases, when high pressure steam is discharged to atmosphere?
a) Sensible heat b) Total enthalpy of steam
c) Saturation temperature d) Specific volume

For flash steam calculation, flash steam quantity available depends upon
a) Condensate pressure and flash steam pressure

When solutions of differing concentrations are separated by a semi-permeable

membrane, water from less concentrated solution passes through the membrane to
dilute the liquid of high concentration. This is called
a) Reverse osmosis b) Ion exchange
c) Softening d) Osmosis

Radiation losses from the surface of a boiler practically

a) Increase with increase in boiler loading
b) Decrease with increase in boiler loading
c) Are independent of boiler loading

Desirable boiler water pH should be ?

a) 5 - 7 b) 7 – 9

For same inlet conditions of the steam, which of the following will generate the maximum
mechanical power ?
a) Condensing turbine

For same inlet conditions of the steam, which of the following will generate the maximum
mechanical power ?
a) Condensing turbine

Which of the following depends on physical properties of fluids as well as geometry of the
b) heat exchanger ?
c) a) Overall heat transfer coefficient

The waste heat boiler application is not suitable for which of the following?
d) a) Gas turbine b) Diesel engine
e) c) Oil fired furnaces d) Hot air dryers

Oxidation of carbon to CO2 yields 8084 kcal/kg of carbon. Oxidation of carbon to CO in

the flue gas yields 2430 kcal/kg of carbon. Oxidation of CO to CO 2 will yield
a) 5654 kCal

In a Heat exchanger with a high LMTD results in a) higher heat

transfer area b) lower heat transfer area

Heat Loss = Heat gain “ is the principle of ____

a) Boiler b) Heat Exchanger

Flash steam quantity per kg of condensate depends upon

a) condensate pressure and flash steam pressure

Which of the following waste heat recovery systems is of thermal storage type?
regenerative burner

The concentration of solids in a boiler is controlled by a) steam venting b) blow down

Insulating material made by blending and melting of alumina and silica is known as a) ceramic fibre
Tangential firing is used in which type of boiler: a)) Pulverised Fuel

_____ is required for the simple estimation of flame temperature of the fuel.
a) Ultimate analysis

When 100 kg of fuel with 60% carbon is burnt with theoretical air, the mass of CO2 released will be a) 319 kg b)
4400 kg c) 4500 kg d) 220 kg

Which of the following heat recovery equipment works on a vapour compression cycle?
heat pump

Which of the following releases large amount of heat per kg during combustion?
a) Hydrogen
In a heat exchanger, for the same heat duty, higher the heat transfer coefficient; a) lower will be the heat transfer
area needed

Which of the following increases, when steam is passed through PRV?

a) specific volume

______ is used as heat carrier in thermic fluid heaters

b) mineral oil

Ceramic fibre gives the maximum energy savings when used in a) continuous furnace b) batch furnace

_____ is required to accommodate expansion of steam lines.

c) expansion loop

Steam mains should be run with a falling slope of … in the direction of steam flow for effective line condensate
drainage) 125 mm in 30 meters
Degasser in water treatment is used to remove
a) carbonic acid

In a boiler Theoretical Air to fuel ratio is 15:1. If 10% excess air is supplied, Flue gas to Fuel ratio will be ____
a) 16:1
b) 17.5:1

Which among the following is most viscous fuel? a) furnace oil

Heat loss through openings in furnaces is directly proportional to a)) fourth power of absolute furnace
temperature

Which of the following is an example of a basic refractory

b) Magnesite

Which property of the refractory determines the deformation under stress?

a) creep

Heat rate is likely to be the least for ________ a) condensing turbine

Which of the following is true of plate heat exchangers a) close approach b) expandable area c) Counter current d)
All of the above

Automatic blowdown controls for boilers work by sensing

d) conductivity and pH

The large difference between GCV and NCV of gaseous fuels is due to
their a) large hydrogen content

When pure hydrogen is burned, with theoretical air, the volume percentage
of nitrogen in flue gas on dry basis will be a) 100%

Dissolved CO2 in boiler feed water when left untreated would result in occurrence
of in boiler tubes
a) water side corrosion

At saturation temp, there can be

a) Hot water b) Wet steam c) Saturated steam d) all of them are possible

Water flows at a rate of 30 m3/hr. at 15oC in a 150 mm bore pipe horizontally. What is the velocity of water
flow in the pipe?
a) 0.47 m/s
b) .
c) Which of the following is not true of condensate recovery? a)) increases boiler blow down

Pinch analysis uses the _____ law of thermodynamics

a) First b) Second c)Third d) Both (a) & (b)

What is the most effective way to avoid ambient air infiltration into a continuous reheating furnace?
a
maintain slightly positive pressure in the furnace .

Select the statement with respect to furnace operations

a) the burner flame should not touch the stock

b) air infiltration leads to oxidation of billets
d) heat loss through openings is proportional to T4

The heat recovery device in which high conductivity bricks are used for storing heat is a)) regenerator

The exhaust from which of the following is not suitable for waste heat boiler application?
a) gas turbine b) hot air dryer c) diesel engine d) furnace

Which of the following has the lowest stoichiometric oxygen demand (kg/kg of fuel)?
a) Sulphur

The head loss due to friction in a pipe is

a
directly proportional to the square of velocity

Which trap is preferred in discharge of condensate recovery from process equipment?

a) Float trap

Corrosion in stack, Air Pre-Heater, Economizer is mainly influenced by _____

b) a)Sulphur content in fuel

Which of the following fuels has the least viscosity?

c) Kerosene

Select the odd one among the following

d) a) Condenser b) Distillation tower c) Evaporator d) Economiser

The working media in a thermo-compressor is

a) d) steam

A rise in conductivity of boiler feed water indicates

a)
c) rise in the total dissolved solids in boiler water

The insulation used for temperatures more than 350oC

b) Calcium silicate

The effectiveness of insulation with ingress of moisture would

a)) decrease

The major limitation of metallic recuperator is -------

.
c) limitation of reduced life for handling temperature more than 1000 oC

In a turbine, the thermodynamic process taking place is

d) b) expansion

Which one of the following fuel has the highest hydrogen content and
lowest sulphur content
a. natural gas

Which of the following yields a low CO2 reading

a) air ingress in flue gas duct

Which of the following is not required for determining economic

thickness of steam line
a) cost of fuel b) boiler efficiency c) enthalpy of steam d) calorific
value of fuel

Which of the following can be used as desiccant in boiler

preservation
a) silica gel b) activated carbon c) un-slaked lime d) all of the
above
 Which of the following boiler utilizes the combination of suspension
firing and great firing
b) spreader stoker boiler

Which fuel among the following needs temperature control during

storage
a) furnace oil

What happens when the float in a float trap develops a puncture

a)) fails to open

The velocity of steam in steam pipe is directly proportional to

specific volume of steam

The unit of overall heat transfer coefficient is

a) W/m2 K

The thermal resistance of an insulation

a) decreases with increased thermal conductivity

The stoichiometric amount of air required to burn 1 kg of methane is

17.39

The chemical used to prevent oxidation in boiler feedwater is

a) sodium sulphite

The best time for intermittent blow down in a boiler

a)) low load under full pressure

Scale losses in reheating furnaces will

a) increase with excess air

Presence of _____ in flue gas confirms incomplete combustion in

furnace
a) CO
On an inverted bucket trap, what happens to the bucket as the trap fills with water
a) it sinks

NOx formation in FBC boilers is minimised because of

b) lower temperatures in the bed and combustion chamber
NOx formation in FBC boilers is minimised because of
c) lower temperatures in the bed and combustion chamber

In which zone of cupola furnace does the conversion of CO2 to CO take place?
reduction zone

If the volatile matter in coal is low, which of the following equipment is the best waste heat
recovery option in a boiler
a) air preheater

Hydrometer is used for the measurement of

a) density

Heat transfer rate for indirect heating application will be less if we heat with
superheated steam

Ceramic coating is used in furnaces because it enhances

b) emissivity

As the pressure of water increases from 1kg/cm2 to 8 kg/cm2, the values

of enthalpy of steam and enthalpy of evaporation respectively
a) increases & decreases

A small quantity of leakage of stored Liquid LPG evaporates to produce about ____ times of
volume of gas.
b) a250

2 m lift of condensate in steam pipe will result in back pressure of

c) a0.2 bar
Specific heat in kCal/kg -0C of fuel oil is in the range of

c) 0.22 – 0.28

Stochiometric air required for combustion of Bagasse is about

b) 3.2

Evaporation ratio (steam to fuel ratio) of an oil fired efficient boiler is in the range of

c) 13 – 14

Pre-heating of combustion air in an oil fired furnace by 200 C will save about ___% of fuel

b) 1

Increase in stack gas temperature of 220 C due to tube fouling or other causes will increase oil consumption in an oil fired
boiler by about.
 a) 1%

Increase of steam pressure has the following effect on steam:

steam temperature goes up and enthalpy of evaporation goes down

Scale losses in reheating furnaces will increase with

b) increase with excess air

An air film inside a steam pipe, made of steel may be _______ times more resistant to heat transfer than the steam pipe.

1500 – 3000

Pressure drop through a steam pipe is inversely proportional to

c) fifth power of diameter

In an oil fired burner, the excess air level _____ towards the highest turndown ratio for efficient combustion.

c) increases

What is the most effective way to avoid ambient air infiltration into a continuous furnace

d) reduce negative pressure inside the furnace

Black body radiation is

d) proportional to the fourth power of the absolute temperature of the body

In which type of furnace operation is a low mass ceramic fiber insulation most suitable to reduce specific fuel consumption
a) batch type furnace

Which loss is the highest in a typical re-heating furnace operating at 13000 C?

a) flue gas loss

In a batch type furnace the following energy efficiency measure would be the most controversial

b) increasing the insulation at the outer surface of the furnace

The most economic insulation is the thickness where …..

c) the sum of energy cost due to losses and insulation depreciation cost is minimum

The emissivity of refractory material….

will decrease with increasing temperature

The heat loss rate from a surface is expressed in

a) Watt

Which statement is incorrect

c) a higher emissivity means lower absorption of heat

In circulating fluidized bed combustion boilers most of the heat transfer takes place…

b) outside of the combustion zone

Which CHP system has the smallest heat to power ratio with the least flexibility to increase or reduce the ratio?
 c) combined cycle

Air compressor alone consumes about ______ of the energy generated in a gas turbine

d) 50-60%

A heat pipe can transfer up to ____ times more thermal energy than copper

e) 100

An economizer raises the boiler feed water by 600 C and therefore saves approximately ___ % of fuel.

b) 10

The working fluid of a steam thermo-compressor is

c) high pressure steam

Radiation recuperators are used when the furnace flue gas temperature is more than

b) 800ºC

Operating the boiler at a pressure less than 80% of the rated pressure will result in

a) reduced boiler feed water pump power

b) increased carryover of water
c) lower boiler exit flue gas temperature
d) all of the above

Amount of oxygen required to burn one kg of hydrogen is

The emissivity of conventional refractory ____ with the increase in temperature

c) decreases

If the pressure of saturated steam is reduced through a pressure reducing valve

) it will get superheated

In selection of a refractory which physical, chemical and other properties of a refractory are important?

(i) melting or softening point

(ii) bulk density,
(iii) porosity
(iv) thermal conductivity
(v) creep at high temperature
(vi) capital costs
With increase in the percentage of excess air for combustion of coal, percentage of CO2 in flue gas.

b) decreases

The lowest excess air is required in a

c) high pressure gas burner

Radiation recuperators are used when the furnace flue gas temperature is more than

800ºC

The emissivity of conventional refractory ____ with the increase in temperature

d) decreases

Scale losses in reheating furnaces will

a) increase with excess air

Steam trap is a device which discharges

air, incondensable gases and condensate

Alumina is a ____ type of refractory

Neutral

The effect of thermal conductivity on thermal resistance of an insulation

decreases with increased thermal conductivity

For even distribution of fluidized air in AFBC boilers, which one of the following is used?
perforated metal distributor plate

The cogeneration system which has high overall system efficiency is

back pressure steam turbine

In a gas turbine, air compressor alone consumes about _____of the energy generated

50-60%

Recuperator as a waste heat recovery system is used mainly in

reheating furnace

Heat transfer by gas radiation in a reheating furnace depends on

a) temperature CO2 concentration water vapor concentration all of the above

If pressure of saturated steam increases then

enthalpy of steam goes up

S-2 List any five energy conservation opportunities in a boiler system.

1. Reduce stack temperature

2. Feed water preheating using economizer
3. Combustion Air preheating
4. Control Incomplete combustion
5. Optimise excess air
6. Blow down heat recovery
7. Reduction of scaling and soot losses
8. Variable speed control of fans, blowers and pumps
9. Optimising efficiency of boiler by loading the boiler to 65-85% of full load
10. Replacement of old and inefficient boiler
11. Proper coal sizing to minimse unburnt losses
12. Proper insulation of boiler to minimize surface/radiation losses
resent in fuel
1. Loss due to evaporation of water formed due to hydrogen in fuel
2. Heat loss due to openings
3. Heat loss through skin
4. Heat storage loss
5. Loss of furnace gases around charging door and opening
6. Heat loss by incomplete combustion
7. Loss of heat by conduction through hearth
8. Loss due to formation of scales

The heat required for phase change from water at 00C to ice is called

Latent heat
The thermostatic trap operates on the principle of:

Differential temperature

Pre-heating of combustion air by 1000C will save about ------% of fuel.

The lower limit to exit flue gas temperature of furnace oil fired system is dependant on ------- in fuel.

Sulphur

The viscosity of furnace oil will be maximum at which of the following temperatures

40oC

The % sulphur content of LSHS is about

0.5

The type of draft used in an oil fired package boiler is

Forced draft
Velocity of steam in a pipe depends on

Specific volume of steam

The heat loss dependant on chemical characteristics of liquid fuel is:

Hydrogen loss

The thermal efficiency of a furnace increases by :

Increasing excess air

The use of ceramic fibre in a batch type furnace results in fuel economy is due to:

Lower heat storage

Which of the following when added to aluminosilicate helps in reducing shrinkage level of ceramic fibre:

MgO

Which of the following fuel requires maximum air for stochiometric combustion?

Hydrogen

Evaporation ratio of an efficient oil fired boiler is in the range of

13 – 14

Which property is the most important for an insulating brick:

Porosity

Air compressor alone consumes about _____ of the energy generated in a gas turbine

50-60%
In circulating fluidized bed combustion boilers most of the heat transfer takes place…

outside of the combustion zone

When pure hydrogen is burn with stochiometric air, percentage nitrogen on volume basis in flue gas on dry basis will be

100%
Flash steam can be recovered from

condensate at high pressure

Reverse osmosis for water treatment involves

removal of total salts

The large difference between GCV and NCV of gaseous fuels is due to their

large hydrogen content

Parallel flow arrangement instead of counter flow arrangement of two streams in a metallic recuperator is chosen because

combustion air also serves the purpose of cooling duct carrying the flue gases.
In which of the following equipment stored heat is used for preheating combustion air

Regenerator

At the same temperature which of the following fuels will have maximum viscosity ?

LSHS

Good opportunity for energy savings from continuous blow down of boiler is by
recovery of flash steam for use in deaerator

Which fuel requires the lowest amount of excess air for combustion?
natural gas

One kg of wood contains 20% moisture and 5% hydrogen by weight. How much water is evaporated during complete
combustion of one kg of wood?
0.65 kg
The pour point of furnace oil is
20oC

“Turndown ratio” for oil fired burners is the ratio of

maximum fuel input to minimum fuel input with same excess air

LPG is predominantly a mixture of propane and ___

butane

An axial compressor is used in conjunction with which of the following

gas turbine

If the pressure of saturated steam is reduced through a pressure reducing valve

it will get superheated

What is the average yield in re-rolling mill furnace?

90-95%

Ceramic fibre gives the maximum energy savings when used in

annealing furnace

Maximum heat transfer to the stock in a reheating furnace is by

radiation

What should be the appropriate coal size for fixed grate coal firing?
75-100 mm

Which type of the following co-generation system has high heat-to-power ratio?
back pressure turbine

In a chain grate coal firing system primary air pressure is 75 mmWC. What should be the secondary air pressure with
respect to primary air pressure?
more than double
The pressure in the heating zone of a furnace should be
slightly positive
In an equipment with steam consumption of 1 ton/hr, the steam trap capacity will be
1.5 ton/hr

The efficiency of a boiler was improved from 70% to 80%. The % fuel savings achieved
 are 12.5%
Which property is most important for a fire brick?
thermal stability at high temperature

Which of the following waste heat recovery systems is of thermal storage type?
regenerative burner

Spontaneous combustion is a loss area in

) coal storage

Which of the following fuel requires the largest amount of excess air for complete combustion?
coal
Which of the following be fired in a gas turbine?
a) natural gas b) LPG c) naptha

A thermal insulator has

low thermal conductivity

The dry saturated steam when throttled to a lower pressure will

superheated

Which of the following boiler type has the lowest permissible boiler drum TDS concentration?
low pressure water tube boiler

Regenerators are widely used in

glass melting furnace

The coefficient of thermal expansion of refractory materials should be

low

The working fluid of a steam thermo-compressor is

) high pressure steam

The limit to reduction of stack temperature in an oil fired boiler is influenced by

% sulphur in oil

The highest percentage of sulphur is present in a) FO

When the liquid LPG evaporates the volume of gas occupied will be
250 times

The air to natural gas (stoichiometric) ratio, by volume, for complete combustion varies
between 9.5:1 to 10:1

For optimum combustion of fuel oil, O2 percentage in flue gases should be maintained at; 2-3%

The steam pressure drop in a steam pipe is inversely proportional to the _____ of pipe diameter
th power

The emissivity of conventional refractories used in a furnace; decreases with increase in temperature

The main constituent of natural gas, accounting for about 95% of the total volume, is; methane

Heat loss through furnace openings is directly proportional to

fourth power of absolute furnace temperature
A power generation system which uses first a gas turbine followed by a steam turbine is called;
combined cycle

Magnesite, chrome magnesite and dolomite are ________ type of refractorybasic

Which loss is the highest in a typical forging furnace operating at 1300 oC? flue gas loss

With increase in the percentage of excess air for combustion of coal, percentage of CO2 in flue gas.
decreases

The lowest level of excess air is required in a;

high pressure gas burner

Pinch analysis uses the ______ law of Thermodynamics

second

Correction factor for LMTD is commonly applicable for;

) cross flow type

Alumina is a …….. type of refractory. neutral

In a reheating furnace, soaking time of a cycle depends typically on

thickness of the charged material

Which of the following in fuel contributes to erosive effect on burner tips during
combustion?

Ash content

The softening temperature of a refractory is indicated by

Pyrometric cone equivalent (PCE)

The recommended TDS level for package fire tube boilers is

3,000 ppm

The emissivity of ceramic coatings used in furnace

) Increases with increase in furnace temperature

The device used for recovering waste heat from the textile drier exhaust is
a) heat wheel

The cogeneration system which has high overall system efficiency is

back pressure steam turbine

The Brayton cycle is a characteristic of

gas turbine

The amount of flash steam generated from the condensate depends on _____
a) sensible heat of high pressure condensate b) sensible heat of flash steam
c) latent heat of flash steam d) all of the above
22. Ten meter lift of condensate in a

Steam mains are run with a slope primarily to

avoid water hammer
Select the correct statement with respect to steam
a) evaporation is a constant temperature process
b) higher the pressure higher is the steam saturation temperature
c) higher the pressure less is the latent heat
d) latent heat at critical point is zero

Insulation used for temperatures more than 350°C is

calcium silicate

Instrument used for measuring billet temperature in a reheating furnace is ___.

infrared pyrometer

In the context of cogeneration turbine, the thermodynamic process taking place is

a) expansion

If 10% air is entrained in a steam system at 3 kg/cm2 g then the saturation temperature
of steam will be
a) less than the saturation temperature at 3 kg/cm2 g

Ideal furnace for melting & alloying is

induction furnace

Glass mineral wool can be applied for temperature range application upto
500 oC

Density of liquid fuels are measured at a reference temperature of

15°C

Commonly used flux medium in a cupola furnace

calcium carbonate

Capillary wick is a part of

heat pipe

The factor that influences atomisation of fuel oil is

a) viscosity

Which of the following is applicable in the preservation of boiler by dry method ?

un-slacked lime activated alumina anhydrous calcium chloride

Which one of the following is true of a water softening process?

It reduces hardness but not TDS

Which property of ceramic coating influences energy savings in furnaces?

Emissivity

The storage heat losses in a batch type furnace can be best reduced by use of
hot face insulating bricks b) hot face ceramic fibre
Which of the following is a synthetic refractory?
SiC

Wick in heat pipe is provided to facilitate

return of condensed liquid

Which of the following requires electrical energy for equipment operation?

heat pump

Pinch analysis of process streams depicts the plot of

temperature vs enthalpy

If the terminal temperature differences at the hot and cold end of a heat
exchanger is same, then the LMTD is
0 oC

Which of the following fuel fired steam boiler will have the least evaporation
ratio?
rice husk

Regenerator is used mainly along with a

high temperature furnace

The device used to upgrade a lower pressure steam to a higher pressure steam is called
thermo compressor

Which agro-residue has the lowest gross calorific value?

) deoiled bran

For stoichiometric combustion of 1 kg of carbon, the required amount of air will be about
11.6 kg

Which of the following in fuel contributes to erosive effect on burner tips?

a) ash

The largest heat loss in the heat balance of a coal fired boiler is due to
dry flue gas loss

The stoichiometric air to natural gas ratio by volume for complete combustion is
9.5-10.5

The insulation material suitable for low temperature application to prevent heat gain is
) polyurethane

Micro turbine can be used to replace _______ for energy savings

PRV

In a condenser, which part of the heat of the steam is rejected?

latent heat