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Power Plant Questions and Answers
1. What are the Engineering documents to be studied
before starting an assignment in a Power Plant?
1. Process and Instruments diagram of various system (P&ID)
2. Automatic Plant Control (APC)
3.Analog fo diagram
!.Analog logic diagram
".#urner management system
$.%e&uence control diagram
'.Permissive( )ri*s and Alarms setting list
+.,unction setting list
-..nit Interloc/ Diagram
10.1*eration and 2aintenance manual
2. What is P&ID?
P&ID is t3e a44reviation for Pi*ing and Instrumentation Diagram. Also
understand as Process and Instrumentation diagram. A draing 3ic3
indicates all t3e *rocess com*onents( *i*ing details along it3 control
and instrumentation details is P&ID.
. !ow "ou will understand the meaning of the s"mbols?
,rom 5egends of t3e draing
#. What is $%&?
#urner 2anagement system 3ic3 includes( Interloc/s( )ri*s condition
and logic for lea/ test( total failure( loss of fame failure( Partial fame
loss and master fuel tri*s. )3is is mainly a system for a *rotection of
furnace e6*losion. 7oever it includes #oiler *rotection interloc/s
suc3 as Drum level 77855 9e3eat *rotection. It also includes
se&uence of start and sto* of fuel :ring e&ui*ment. ,%%%;;,urnace
%afegaurd %u*ervisory %ystem is also used 4y some manufacturers.
'. What is &Q(?
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Permissive( )ri* interloc/s and 1*eration and Control of fans( *um*s(
<anes( <alves and Dam*ers( etc.(
). What is *nit Interloc+ Diagram?
)3is includes Interloc/s( 5ogic 4eteen 2ain e&ui*ments suc3 as
#oiler( tur4ine( =enerator( =enerator transformer( .nit transformer.
,. What is the &tandard a--lied for $%&?
>ational ,ire Protection Association ; >,PA( .%A. >,PA +" covers 4oiler
and various fuel :ring
.. What are the -re/commissioning acti0ities in $oiler1
2urbine1 3enerator and others?
#oiler ?
a. )rial run of Au6iliaries 3ic3 includes t3e logic con:rmation using
simulated in*ut8out*ut signal from :eld8mars3alling *anel
4. Con:rmation of logic and *rotection for #2%
c. )rial 5ig3t u* of 4urners
d. Al/ali 4oil;out
e. Acid cleaning and *assivation
f. %team 4loing
g. %afety valves testing
)ur4ine ?
a. )rial run of Au6iliaries 3ic3 includes t3e logic con:rmation using
simulated in*ut8out*ut signal from :eld8mars3alling *anel
4. 1il fus3ing
c. )rial start;u*
d. %*eed test( con:rmation of Auto 9un;u* %ystem (A9%)
=enerator ?
a. )rial run of Au6iliaries 3ic3 includes t3e logic con:rmation using
simulated in*ut8out*ut signal from :eld8mars3alling *anel
4. #ac/ c3arging of )ransformer. %ome Poer com*anies are not
alloing t3is test. )ransformers s3all 4e test after generator
commissioning
c. Con:rmation of @6citation( A<9 %ystem
d. 1C and %C )est
e. %ync3roniAing and initial loading
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4. What are the -arameters shall be monitored for
e5ui-ment6s trial o-eration?
Current( 4earing tem*erature( Binding )em*erature( >oise <i4ration(
s*eed( Cooling ater tem*erature( 5u4e oil tem*erature(
17. Describe the method for !igh 8oltage 2est for
%otors?
2ay 4e for t3e :rst time t3e motor ill 4e tested for 1." 6 < 9ate C 1
D< ( DC). If AC is used it ill 4e 1." 6 < 9ated 6 %&rt 2 C 1." D<. At site
it is advisa4le to test for rated voltage.
11. What is the action to be ta+en if the bearing
tem-erature increases for a greased bearing?

=rease s3all 4e re*laced.
12. What is the allowable bearing tem-erature?
42 Deg.C to 120 Deg.C
1. What is the allowable 0ibration le0el?
100 micron
1#. What is allowable winding tem-erature?
100 t0 120 Deg.C
1'. What are the t"-es of limit switches -ro0ided in an
electrical 0al0e actuator?
5imit or *osition sitc3es and )or&ue sitc3ed 4ot3 for o*ening and
closing
1). !ow to set/u- the limit switches for di9erent t"-e of
0al0es?
All ty*es of valves s3all 4e set to sto* 4y limit sitc3 ( *osition sitc3)
u*on o*eing. )or&ue sitc3 s3all 4e used as 4ac/;u*. Closing s3all 4e
sto*ed 4y limit or tor&ue sitc3 de*ending u*on t3e ty*e of valve.
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=lo4e <alve ; 4y tor&ue sitc3( =ate valve avd ot3ers 4y limit sitc3
and tor&ue sitc3 s3all 4e used as 4ac/;u*.
1,. What action shall be ta+en if a electrical actuator
tri-s on 2or5ue limit switch u-on start o-ening?
>ormally in case of =lo4e valve 3ere valve close ill 4e limited 4y
tor&ue sitc3 t3e valve ill sto* u*on receiving o*en command 4y t3e
activation of o*en tor&ue sitc3.
(o*eration solution)
; <alve s3all 4e o*en manually for one or more turns.
( Control solution)
; )3e o*en tor&ue sitc3 s3all 4e disa4led for :ve *ercent.
1.. What is the control solution to o0er come the
-roblem of electrical 0al0e actuator tri--ing on 2or5ue
limit switch while start o-ening?
#y;*ass o*en tor&ue sitc3 4y close limit sic3 for 3E o*en. )3e limit
sitc3 s3all o*en and 4ring t3e o*en tor&ue sitc3 from 3 to 100E
o*en.
14. What are the -ossible reasons for a motor to tri- b"
Instantaneous o0er current and what action to be ta+en?
<oltage may 4e 3ig3er t3an rated value or insulation may 4e failed.
Con:rmed 4y t3e @lectrical @ngineer 4y c3ec/ing t3e
voltage8meggaring t3e motor( cal4e( etc.
27. What will be e9ect when a motor dri0en e5ui-ment
is started on load?
)3e starting current 3ic3 ill 4e $ to + times t3e 9ated current ill
remain same( unless t3e su**ly voltage is 3ig3er t3an rated. )3e
starting time ill increase and t3e **e&ui*ment may tri* on t3ermal
over load.
21. What is &talling with res-ect to :an?
B3en a fan is loaded it3 disc3arge dam*er is closed or no t3roug3
o*ening *ass at t3e disc3arge( t3e *ressure ill 4e 3ig3er t3an t3e
normal for t3e fo. )3is cause( esca*e of air in 4eteen t3e casing
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and t3e 4lades from disc3arge to suction. )3is ill cause in rreduction
of *ressure. )3e fan ill 4e3ave t3e same ay. )3e *ressure ill
increase and decrease and increase. )3is is /non as %talling of a fan.
)3e current also ill 4e3ave in t3e same cycle. If alloed( t3e 4lades
may 4rea/ and ill cause a maFor demage.
22. Which :an will su9er &talling and wh"?
A6ial fans.
,orced draft fan ill suGer stalling. %ince it 3as a varia4le
resistance device
(9otating air 3eater) B3ose resistance to fo ill increase due
to c3o/ing during o*eration are mal function of secondary air
dam*er .
2. What are the starting interloc+s for :an?
%uction dam*er closed is t3e minimum interloc/ for a fan 4efore start.
2#. What are starting interloc+s for -um-?
%uction valve o*en is t3e minimum interloc/ for a *um* 4efore start.
2'. Wh" minimum recirculation is necessar" for a -um-
and how much the 0alue will be and what are methods to
-redict the loss of minimum ;ow?
Bit3out re;circulation( t3e fuid in t3e *um* ill 4e c3urned re*eatedly
resulting in 3eating8va*oriAation u* of t3e fuild.)3is ill result in
sealing glands8*um* internals 4eing damaged. )y*ically( inferred from
lo fo 4y ,lo sitc3es In suction *i*es or 3ig3 diGerential
tem*erature 4eteen suction and disc3arge 4y tem*erature sic3e.
2). What are the tri- commands for a :an?
)y*ical )ri* interloc/s for fans are? #earing )em* 19 <i4ration
7ig3(5u4e oil *ress 5o( @lectrical sitc3gear faults.
2,. What are the tri- commands for a -um-?
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)y*ical )ri* interloc/s for Pum*s are? #earing )em* 19 <i4ration
7ig3(5u4e oil *ress 5o( %uction valve Closed ( @lectrical sitc3gear
faults.
2.. E<-lain the balance drum of a $:P?
>ormally t3e diGerential *ressure 4eteen disc3arge and suction sides
of #oiler ,eed Pum*s are &uite 3ig3. Due to t3is( t3e rotor section
e6*eriences very 3ig3 trust in one direction. )3e movement of rotor
(A6ial s3ift)( if it e6ceeds manufacturerHs tolerances( ill result in
ru44ing of mec3anical seals and damage t3e same. A #alance Drum is
created 4y interconnecting suction and disc3arge sides suita4ly and
t3e ear out of seals can e4 inferred 4y measuring #alance drum
*ressure.
24. E<-lain the -rocedure of alignment of a rotating
e5ui-ment? What is re0erse and soft foot alignment?
)o rotating s3aft s3all 4e aligned suc3 t3at t3e s3ear forces and
4ending moments at t3e cou*ling are Aero.
,inal alignment of rotors are o4tained 4y adFusting t3e 4earings
( for tur4ine rotors) and 4y adFusting t3e motor for Pum*s( fans( etc
to give *arallelism and concentricity at eac3 *air of cou*lings.
)3e alignment is carried out 4y measuring t3e face ga*s and
*eri*3ery errors 4eteen cou*lings.
=a* measurements( using suita4le gauges( are ta/en at t3e to*(
4ottom and to side *ositions and a re*eat set ta/en it3 4ot3
s3afts rotated t3roug3 1+0 deg. )3e average of t3e to sets
indicates t3e true *arallelism of t3e cou*ling faces( eliminating any
errors due to out of trut3 4eteen cou*lings and s3aft.
Concentricity is c3ec/ed 4y measuring 4eteen t3e *eri*3eries of
t3e to cou*lings( using eit3er dial indicators or feeler gauges( to a
:nger attac3ed to one of t3e cou*ling. )o eliminate cou*ling errors(
4ot3 s3afts are turned toget3er and readings ta/en at t3e to*(
4ottom and to side *ositions.
Calculations using ratios and similar triangles( ta/ing account of
s3aft lengt3( distance 4eteen 4earings and cou*ling diameter(
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determine t3e adFustment re&uired at t3e 4earings to o4tain s3aft
alignment.
Bit3 solidly Icou*led s3afts( it is usual to or/ to very close
tolerances of t3e order of *lus8minus 0.02" mm.
7. What is mechanical seal?
,or any *um*( t3ere ill 4e glands 4eteen t3e rotot and t3e 4ody at
t3e end 4efore 4earing. )3is is to avoid lea/ along t3e s3aft. In a 3ig3
*ressure *um*s( instead of as4estos gland ro*es( a self lu4ricating
material made of car4on and iron ill 4e used. )3is is called
2ec3anical seal.
1. What is the 3as+et of 0al0es? =ame the t"-e of
bonnet gas+ets and gland gas+ets for 0al0es?
)3e soft material used 4eteen t3e 4ody and t3e 4onnet of a valve is
called gas/ets. As4estos reinforced Pa*er( ru44er(
metallic gas/ets (%*ira/et gas/ets)( etc.
2. !ow to categori>e the t"-e of boilers?
a) According to t3e use I .tility #oiler( Processing ty*e #oiler.
4) According to t3e tu4e content ; ,ire tu4e ( Bater tu4e #oilers.
c) According to t3e furnace *osition I @6ternally :red &
Internally :red 4oiler.
d) According to t3e circulation ; >atural & ,orced circulation.
e) According to furnace *ressure I #alanced draft & *ressuriAed
. What are the &econdar" Air Dam-ers and how the"
di9er between wall ?red and corner ?red boilers?
)3e dam*er controlling t3e com4ustion air to fuel at t3e 4urner is
/non as %econdary air. )3e air 3ic3 is used to trans*ort fuel to t3e
4urner is Primary air. >ormally secondary air ill 4e admitted very
close to t3e fuel. In a all :red 4oiler t3e secondary air ill 4e s*inned
around t3e fuel s*ary. If t3e secondary air a6ial velocity com*onent is
greater t3an fame *ro4agation velocity( t3en t3e fame ill 4ecome
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unsta4le. 7ence t3e e6cess air ill 4e su**lied at t3e outer circle. )3is
air is /non as )eritery air. In a corner :red 4oiler( t3e secondary air is
/non as ,uel air( t3e dam*er is called ,AD. )3e air ill 4e admitted
a6ially at t3e 4ottom and to* of t3e fuel noAAle and ill rotate at t3e
*3eri*eral of t3e :re 4all. )3e e6cess air ill 4e admitted at 3e ne6t
level of eac3 ,AD outlet and called Au6iliary air and dam*er is called
AAD.
#. !ow to o-erate the &ADs in a wall ?red and corner
?red boiler?
%ADs ill 4e o*ened fully in all :red 4oiler. )3e air fo to eac3
4urner in service ill 4e alays e&ual. 7ence un4alanced loading of
fuel 4eteen mills s3all 4e avoided e6ce*t starting. In a corner :ring(
t3e fuel air dam*er ill 4e function of mill load. )3e AAd ill maintain
t3e Bind;4o68furnace diGerential *ressure constant at !0 mm BC5
4efore any mill is in service and at 1+0 mmBC5 after any mill is ta/en
to service.
'. (an it be -ossible to o-en the inlet 0ane of an ID:
during trial run and wh"?
It may not 4e *ossi4le. )3e fan may 4e over loaded. A fan 3andle
volume. B3en t3e inlet vane is fully o*en( t3e volume of gas8air ill 4e
t3e ma6imum. ID ,an 3andles fue gas at 120 to 1!0 Deg.C. )3e
density of gas ill 4e less com*ared to air. ( Air density ; 1.2- Dg823 at
1" Deg.C) . )3e load of motor is *ro*ortion to mass of t3e gas. 7ence
t3e motor may over loaded. Care s3all 4e ta/en during trial run of ID
,an. )3e inlet vane s3all 4e o*ened to t3e rated current.
). What are the chemical cleanings for a boiler and
end-oint for them?
Al/ali 4oil out ; It uses Al/ali suc3 as >A17( CAC13( etc. )3e *ur*ose is
to remove grease in t3e tu4es. )3e 4oiler ill 4e *ressurised to 20
Dg8cm2 and /e*t for 2! to !+ 3ours. #lo;don ill 4e o*ened for 1
min for every 1 3our.@nd *oint is no traces of grease in t3e eJuent.
Acid Cleaning I It uses diluted %ul*3ric acid. )3e *ur*ose is to remove
loose mill scales in t3e 4oiler tu4es. )3e end *oint is t3e saturation of
iron in t3e mi6ture or 2 3ours( 3ic3 is early.%ometime acid cleaning at
very mild concentration ill 4e a**lied for old 4oiler to remove any
scaling in t3e ater all tu4es.
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Passivation I )3e reaction of acid s3all 4e cleared after acid cleaning.
,or t3is *ur*ose( t3e mi6ture Ammonia *3os*3ate at 200 **m and
7ydroAene at 200 **m ill 4e left to eva*orate at 20 Dg8cm2 for 2!
3ours.
)3e eGectiveness ill 4e con:rmed 4y t3e colour on t3e coating tu4e
inside.
All c3emical cleaning are a**lied for ater all tu4es. %7 s3all 4e
*rotected during Acid cleaning.
,. What is the -rocedure for Al+ali/boilout1 Acid
cleaning1 -assi0ation1 etc.?
As a4ove
.. What is steam blowing? Wh" it is necessar"? !ow
man" t"-e of steam blowing are in the -ractice? What is
deciding factor for the com-letion of steam blowing and
who shall decide the com-letion?
A *rocess underta/en during initial *lant installation( to remove any
mill scale in %7 tu4es and *i*es 4y 4loing steam and venting out t3e
same is /non as steam 4loing. Continuous and PuG %team 4lo
met3ods are used. In continuous met3od t3e 4oiler s3all 4e *re*ared
for full load and t3e steam at full load fo( *ressure and tem*erature
s3all 4e 4lon for some 3ours. In PuKng met3od( *ressure in t3e
4oiler ill 4e raised to 2"0 Deg.C( at around !0 4ar( and t3e sto* valve
in t3e tem*orary *i*e is o*ened &uic/ly. )3is ill create a sudden
c3ange in velocity in t3e *i*e. It is claimed t3at t3is t3e 4est
economical met3od. A target steel *late is *ut at t3e end of t3e
*i*eline sections and t3e same is o4served for t3e indentations after
t3e steam 4lo to esta4lis3 t3e cleanliness of t3e steam *i*es. %ince
t3e steam admitted to tur4ine s3ould not contain any contaminant
(damages t3e tur4ine internals)( t3e )ur4ine commissioning in;c3arge
ill give clearance for t3e com*letion of satisfactory steam 4loing
o*eration.
4. What is safet" 0al0e and @elief 0al0e?
A valve *rovided on any *ressure vessel 3ic3 ill o*en to release
t3e *ressuriAing media 3en t3e *ressure e6ceeds t3e set value.
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%afety valve ill o*en at a *reset value and seat again at a :6ed
reset *ressure.
9elief valve also ill o*en at set value and sit 3en t3e *ressure is
less t3an set value.
#7. !ow man" safet" 0al0es shall be -ro0ided for a
boiler and where?
)3e folloing are t3e main safety valves ty*ically in a 4oiler ?
#oiler drum (5) ; 2 nos
#oiler drum (9) ; 1 no
%u*er 3eater outlet (9) ; 1 no
9e3eater Inlet (5) ; 1 no
9e3eater 1utlet (9) ; 2 nos
9e3eater 1utlet (5) ; 1 no
%u*er 3eater 1utlet (5) ; 2 nos
#1. !ow to set a safet" 0al0e? What is Aift and $low
down? !ow to adBust them?
9aise 4oiler steam *ressure. >ear set *ressure( lift t3e stem manually
4y using ro*e on t3e 3and *o* level. Increase *ressure and con:rm
t3at t3e valve is o*ening at t3e re&uired set value. %tart from t3e
3ig3est set *ressure valve. Lac/ close t3e lo set *ressure valves.
Con:rm 4lo don. It s3all 4e 4eteen 2 to "E.
5ift ? )3e amount of raise of stem 3ile lifting is called MliftN.
#lo don ? )3e diGerence 4eteen set *ressure & reseat *ressure
@6*ressed in *ercentage of set *ressure.
AdFustment ?
5oer ring adF ?; )o set a clear *o**ing( to close sloly. ()o avoid
%immering & c3attering ).
)o reduce simmer( move t3e loer ring
u*ard
ie. Anticloc/ise direction.
1 notc3 O !2.2/sc.
.**er ring adF. ?; )o adFust 4lo don .
)o reduce 4lo don( move t3e u**er ring
u*ard(
ie.( turn anticloc/ise.
)o increase 4lo don ( move t3e ring
donard.
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#2. What is electrical relief 0al0e and how to set u-?
@lectrical relief valve is used in 2.% line to relieve t3e e6cess *ressure(
t3ere4y reduce t3e fre&uency of lifting t3e 2.% line %.7 safety valve.
)3e @9< is set for lifting electrically (4y solenoid ) to o*erate 4elo
t3e set *ressure of su*er 3eater safety valve.
#. What is the boiler e<-ansion? !ow much will be the
e<-ansion of a boiler at burner le0el?
#oilers ill e6*and 3en su4Fect to 3eating. )o allo t3e e6*ansion(
t3ey ill 4e eit3er su**orted from to* 4y 3anging or from 4ottom.
As a t3um4 rule( for every 100 Deg.C. *er meter( t3e e6*ansion
from :6ed su**ort( ill 4e 1." mm.
A +00 )87 ca*acity 4oiler( ill e6*and to a ma6imum at t3e end ill
4e 1"0 mm.
##. !ow man" -lace the e<-ansion will be chec+ed?
Drum( in t3e furnace at least 3 *laces( 4urner area and at t3e end.
#'. What is the function of $uc+s/ sta" in a boiler?
)3e furnace ill e6*and in all t3e 3 a6is. )o /ee* t3e s3a*e it ill 4e
:6ed at t3e middle of eac3 side 4y a strong 4eams and moving
connections ill 4e *rovided at t3e corners. )3is frame or structure
is called #uc/s;stay.
#). What is steam se-arators and how man" t"-es will
be there in a drum?
)3e steam from t3e raiser tu4es ill 4e mi6ture of steam and ater
*articles. )3is is /non as et steam. %team s3all 4e se*arated
from ater *articles. )3e devices used are called steam se*arators.
)3is functions are done in t3e drum. )3e steam from raisers ate
ta/en 4ac/ to drum and t3ere it is made to *ass t3roug3 t3e
se*arators.
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Centrifugal ty*e of 4uc/ets of many in num4er ill 4e *rovided.
)3is is Primary se*arators. )3e steam ill 4e *assed t3roug3
radiator /ind of se*arators 4efore leaving t3e drum at t3e to*. )3is
is /non as %econdary se*arators.
#,. What is su-er heater and how man" t"-es are
there?
Additional 3eat is added 4y increasing t3e steam tem*erature
t3roug3 4undle of tu4es.
)3ese are %u*er 3eaters.
)3ere are to /ind of su*er 3eaters used in a 4oiler. Convection
ty*es are *laced in t3e second *ass and 3eat transfer ill 4e from
fue gas 4y convection.
)3e e6it coils ill 4e *laced at t3e to* of furnace. 7eat transfer ill
4e mainly 4y 9adiation. )3is is t3e ,inal su*er 3eaters.
B3en t3e tu4es are staggered 3oriAontally( 4eteen t3e to
3eaders( t3ey can 4e *rovided it3 drains. )3is is /non as
draina4le su*er 3eaters. )3is arrangement is *racticed in oil8gas
:red 4oilers. In a coal :red 4oiler( t3ey are *laced vertically and
/non as Platen su*er 3eaters. )3e condensate in t3e 4ottom of
eac3 coil s3all 4e made to eva*orate to allo *assage for steam.
)3is is ac3ieved 4y slo :ring it3 vent o*en. )3e starting time ill
4e more in t3is case 4efore closing vents.
#.. What is economi>er? !ow to -rotect the economi>er
from e0a-oration?
)o increase t3e 4oiler eKciency( t3e feed ater is 3eated furt3er
using fue gas. )3is section of 3eat recovery coils are /non as
@conomiAers.
2ain criteria is t3at t3e steaming s3all 4e avoided for smoot3 fo
of feed ater in to drum. 1t3erise 3ammering ill ta/e *lace in
t3e feeder tu4es.
)3e fue gas tem*erature at t3e e6it of economiAers s3all 4e
maintained ell a4ove sul*3er de *oint for t3e fuel in use.
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A feeder *i*e it3 non return valve and an isolating valve (for
maintenance) ill 4e connected at t3e 4ottom 3eader of t3e
economiAer. )3is /ee* t3e ater level in t3e economiAer ill 4e
same as t3at of drum 3en t3ere is no feeding from 4oiler feed
*um*. )3is ill avoid eva*oration in t3e economiAer.
#4. What is the need for an Airheater? !ow man" t"-es
are there? What is cold end corrosion? !ow to -rotect
from cold end corrosion?
If t3e 3eat in*ut from fuel is e6tracted as muc3 as *ossi4le( t3e
eKciency of t3e 4oiler ill increase. )3e fue gas tem*erature at
t3e outlet of economiAer is around 300 Deg.C. )3e *rocess media(
3ic3 is less t3an 300 Deg.C.( is air used for com4ustion. )3e 3eat
e6c3anger used to e6tract t3e 3eat from fue gas after economiAer
to air is called Air 3eater.
)o ty*es are in t3e mar/et. 1ne is )u4ular and t3e ot3er one is
9otary air 3eater. )u4ular air 3eater is used in small 4oilers. 9otary
air 3eaters are used in large siAe 4oilers a4ove 110 2B.
)3e average tem*erature 4eteen t3e e6ist fue gas and entering
air is t3e tem*erature at t3e e6it of air 3eater. )3is end is called
cold end.
If t3e cold end tem*erature goes 4elo sul*3ur de *oint( su*3uric
acid ill form on t3e metal. )3is ill cause corrosion of t3e metal.
)3e metal s3all 4e *rotected from t3is *ossi4le corrosion.
1ne met3od is using non metallic material at t3e cold end. 9otten
iron and Ceramic are used in rotary air 3eaters. Anot3er met3od is
to /ee* t3e cold end tem*erature 3ig3er t3an sul*3ur de *oint.
,or t3is *ur*ose( t3e air ill 4e *re;3eated 4y steam 4efore
admitting to rotary air 3eater. #ot3 of t3em are *racticed in
maFority cases.

'7. What is &(A!? And how man" t"-es of them in the
mar+et?
As e6*lained a4ove t3e air ill 4e *re;3eated 4efore admitting to
rotary air 3eater using steam. )3is 3eat e6c3anger is /non as
%team Coil Air 7eater (%CA7).
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Coil ty*e and vertical tu4e are t3e to ty*es used in t3e mar/et.
Coil ty*e is using sim*le instruments and control. #ut eKciency is
lo. )3e )ra* used at t3e outlet of steam can only e6tract t3e latent
3eat from t3e steam. )3e steam *ressure ill 4e 10 to 1! 4ar. )3e
e6it tem*erature ill 4e around 200 Deg.C. In a vertical tu4ular
ty*e t3e ater is maintained in t3e tu4es and t3e 3eat can 4e
e6tracted as lo as '0 to 100 Deg.C.
'1. What are the -re/commissioning acti0ities of a
steam turbine?
a. %team 4loing of *i*es
4. 1il fus3ing
c. <acuum test
d. Initial rolling
e. )rial rolling
'2. What are the -re/commissioning acti0ities of
3enerator?
a. @6citation
4. 1*en Circuit )est
c. %3ort Circuit )est
d. %ync3roniAing
'. !ow to chec+ the 3enerator and *nit 2ransformers?
=enerator is tested 4y t3e a4ove test.
.nit )ransformer
a. 1il centrifuging
4. 1*en Circuit )est
c. %3ort Circuit )est
.nit transformer is c3ec/ed 4y 4ac/ c3arging. 7oever some
com*anies ill nto agree for 4ac/ c3arging. )3ey are tested using
=enerator 4y sloly increasing voltage.
'#. !ow man" t"-es of o0ers-eed tri-s are a0ailable for
turbine and what are the setting?
@lectrical 1ver s*eed *rotection
2ec3anical 1ver s*eed *rotection
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)ri* setting for @lectrical is 1.0" times t3e rated s*eed and t3at of
2ec3anical is 1.1 times t3e rated s*eed.
A PID s*eed control ill 4e *rovided as over;ride to t3e load control.
A )roo* control also ill 4e *rovided it3 0.2" 7A dead4and. )3e
normal troo* setting ill 4e ! to +E . )3e range ill 4e u*to 20E.
)roo* control is a *ro*ortional control. @6am*le !E troo* ill
*roduce a 100E out*ut it3 a deviation 2 7A. Assume a .nit is
running at full load it3 =1< demand as -"E. )3e =1< demand
ill 4e 0 at "1.- 7A.
In addition to avoid a tur4ine tri**ing due to overs*eed(
Antici*atory 5oad %c3edule logic ill 4e *rovided. In suc3 case
during a load reduction more t3an 2"E( t3e electrical and t3ermal
load ill 4e com*ared and if t3ermal load 3ig3 after 2 sec( t3e =1<
ill 4e demanded to close fully for a fe second and release to t3e
*osition re&uired 4y t3e electrical load 4efore closing.

''. What is s"nchroni>ing? !ow to s"nchroni>e?
Connecting an incoming *oer su**ly to t3e grid or e6isting
system is %ync3roniAing.
,re&uency( *3ase angle and magnitude of voltage s3all 4e same for
4ot3 incoming and running *oer su**ly. >ormally an indicating
instrument ill 4e *rovided to com*are t3em. B3en t3ey are
satis:ed t3e meter ill 4e at 12 1Pcloc/ *osition. )3e 4rea/er s3all
4e closed at t3is condition.
'). What is the function of A8@ and AQ@? !ow to
maintain the e<-ort -ower factor?
A<9 I )o maintain t3e terminal voltage of a =enerator
AQ9 I )o maintain t3e Poer ,actor
.sing .nit )ransformer ta* c3ange in conFunction it3 AQ9( t3e
*oer factor of t3e e6*ort *oer factor can 4e maintained.
',. What is the function of E<citer and how man" t"-es
of e<citers are there?
@6citer is t3e device 3ic3 is *roviding t3e su**ly to *rovide :eld
current of a generator.
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2ec3anical it3 a normal DC generator
%tatic @6citer I Provide necessary su**ly from t3e AC su**ly 4y
rectifying 4y using )3yristors.
'.. What is baring gear?
>ormally( t3e )= rotor is a 3eavy mass and rests on t3e 4earings(
3en no steam is admitted to )ur4ine. In order to *revent metal to
metal contact8erosion during initial steam admission( t3e rotor mass is
lifted (Lac/ed u*) slig3tly aay from 4earing metal t3ru t3in :lm of
3ig3 *ressure 1il.#aring =ear is t3e motive force to 9otate t3e )=
rotor in slo s*eed. )3is is needed to faciliate easy rotation of )= on
steam admission. )3e )= rotor is also *ut on 4arring on )ur4ine sto*
to assist in uniform cooling of rotor mass until t3e tur4ine metal
reac3es t3e room tem*erature.
'4. What is Cac+ing oil -um-?
A se*arate 3ig3 *ressure oil *um*ing system is designed to facilitate
#aring o*eration and t3e Pum* is /non as Lac/ing oil *um*. )3is
*um* is sitc3ed on 4ot3 at t3e t3e 4eginning of #aring o*eration.
)7. What is *P& and what is its function and what are
their com-onents?
.P% is .n;interru*ta4le Poer %u**ly %ystem. )3e main com*onenets
are C3arger( Inverter and #attery 4an/. >ormally(t3ese are used to
*rovide *oer su**ly for limited *eriod to Control and Instrumentation
systems during 2ain AC *oer failure.
)1. !ow to test and maintain $atter"?
#y *eriodically measuring @nd cell voltage and t3e density of Acid to
4e it3in limits. Acid )o**ing u* is needed if density goes
lo.>oadays( 2aintenance free 4atteries are availa4le( 3ose life is
10;;1" years.
)2. What is the function of (ircuit $rea+ers and what
are the t"-es and their a--lications?
A device used to close81*en a electrical e&ui*ment to t3e *oer
su**ly is called
Circuit #rea/er.
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)3ey are named 4y t3e cooling or arc &uenc3ing media used in t3e
device. B3en an e&ui*ment is disconnected from a *oer su**ly(
t3e *otential strengt3 ill 4e more. )3is ill *roduce 3eat in
4eteen t3e surfaces and cause t3e media to ioniAe. )3is is s*ar/.
If t3e s*ar/ continues and it ill 4e called as Arc. )3e 3eat energy
ill damage t3e device.
)o reduce t3e eGect of 3eat generation( t3e area *rovided to t3e
4rea/er ill 4e increased. )3e time to se*arate t3e e&ui*ment
from *oer su**ly ill 4e minimiAed 4y using s*ring. 7oever t3e
arc can 4e controlled 4y cooling or using media 3ic3 can
it3stand 3ig3 *otential strengt3.
Air( 1il and %,$ gas are some of t3e &uenc3ing media used in a
circuit 4rea/er. )3e 4rea/er is named 4ased on t3em. )3ey are Air
Circuit #rea/er (AC#)( 1il Circuit #rea/er (1C#) and %,$ Circuit
#rea/er.
). What are the main -arameters shall be controlled
during start/u- of turbine?
Pressure and )em*erature are t3e steam *arameters to 4e matc3ed
it3 tur4ine metal tem*erature.
)#. What is the function of dust collectors and what are
the t"-es of dust collectors are there? What are the limits
of the -reci-itators? What is the en0ironment limits?
As3 and un4urned car4on ill leave t3e furnace along it3 fue gas.
)3ese dusts s3all not 4e left to c3imney. )o control *ollution in t3e
atmos*3ere( t3e dust s3all 4e collected 4y some means 4efore
going to c3imney. )3e e&ui*ment serves t3is function is dust
collectors.
2ec3anical se*arators( @lectro static *reci*itator and 4ag :lters are
some of t3e dust collectors used commercially in 4oilers.
)3e :nesse is t3e limit in t3e case of mec3anical se*arators .
@lectrical resistance is t3e limit for @%P
!0 mg823 of dust 4urden is acce*ted in many countries. 7oever
dust 4urden s*eci:ed is 20 mg823.

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)'. E<-lain the -rinci-le of EP and their com-onents?
What ma" the reason for low current and !igh 0oltage
and !igh current and Aow 0oltage? !ow to set the
o-erating condition manuall"?
2wo Electrodes at high -otential di9erence of D( su--l" will
be build in the ;ue gas -ath after air heater before ID fan.
2he emitting electrode is a thin wire. 2he -otential strength
around wire will ioni>e the gas. 2his is +nown as (orona. 2he
ioni>ed gas will be with Electrons and -ositi0e ions. 2he
collecting electrode are -lates and -ro0ide large area.
2he electrons are tra0eling from discharge electrode
towards the collecting electrode at a high 0elocit".
D =ormall" the ga- is 2'7 mmE.2he ;ue gas consists of dust
is -assing through the electrode at a low 0elocit" of 1 mFsec
or less. 2he dust -articles are bombarded b" the electrons
and attached to the dust. 2he dust will be now charge G0el".
2he" are attracted b" collecting electrode -lates. 2he
0elocit" at which the dust is mo0ing towards collectors is
+nown as migration 0elocit".
%igrations 0elocit" will be more than the gas 0elocit". 2his
bring the dust to the collectors. 2here the" are attached to
the -lates. 2he eHcienc" of a >one of E&P will be around
47I.
Discharge electrodes1 collecting electrodes1 Insulators1 high
0oltage transformerFrecti?ers1 hammering s"stems for the
electrodes and controllers are some of the main
com-onents of an E&P.
Aow current and !igh 0oltage is caused b" the de-osit of
?ne dust on discharge electrode.
!igh current and low 0oltage is caused b" de-osit of coarse
dust on the collecting -lates. !igh resisti0e dust will ma+e
the condition worst in this case. 2here will be corona near
collecting -lated when high -otential strength is
established b" the dust de-osit. 2his -henomenon is called
$ac+ (arona. 2he electrons from this corona will combine
with the -ositi0e ion from the main corona and similarl" the
-ositi0e ion from bac+ corona will combine easil" with
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electrons from main corona. 2he dust will esca-e from E&P
to chimne".
When control is on %anual1 increase the current until there
is s-ar+. Aea0e at a le0el where 2 to ' s-ar+sFmin is
occurring.
)). What is the &mo+e Densit" and what is its
regulation limits and o-eration limits?
,lue gas consists of large &uantity of C1 is smo/e. B3en lig3t can
*ass t3roug3 t3e fue gas fully( t3e smo/e density is 0E. B3en no
lig3t *ass t3roug3 t3e fue gas( smo/e density is 100E.
%mo/e emission of 20E in t3e c3imney is alloed. 7oever a good
*ractice is to o*erate a 4oiler it3in 0 to "E smo/e density in t3e
fue gas.
1*eration of a 4oiler at more t3an !0E for more t3an " min in a day
is an oGense and su4Fect to *enalty 4y =overnment.
),. What is the function of (himne" and its -rinci-le?
)3e main function of c3imney is to dis*ose t3e fue gas at a 3ig3 level
so as s*read it to a ide area and t3ere4y reducing t3e *ollution.
).. What are the chemical -arameters shall be
monitored at the chimne" e<it?
C1( C12( %16( >16( dust 4urden & smo/e density.
)4. !ow to reduce &J< emission?
#y using fuel it3 loer sul*3ur content and also 4y installing de;
sul*3urisation *lants to remove sul*3ur from fue gas at c3imney.
,7. !ow to control =J< emission?
Kee-ing the ;ame tem-erature less than 4'7 Deg.( will
reduce the =JL emmission. 2he achie0e the abo0e condition
the J2 in the air can be reduced to 1.I b" adding ;ue gas
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from economi>er outlet in the wind/bo<. Alternatel" air can
be admitted at the to- of the ;ame.
,1. What is the function of Air/eBector? !ow man" t"-es
are there?
>ormally @Fectors are used for creation of vacuum in a vessel. )3ere
are to ty*es;;Air eFectors and %team eFectors.
,2. What is the function of condenser?
Condensers are used to remove 7eat from %team and t3ere4y convert
steam into ater. >ormally t3is is at t3e steam e6it of )ur4ine.
,. What is the function of cooling water? !ow man"
t"-es of cooling s"stems are there?
A circulating ater system at atmos*3eric tem*erature is used to
remove e63aust medium tem*erature is Cooling ater system.
Condenser cooling ater system and Au6iliary Cooling ater
system are t3e 2 main cooling ater systems in use in a *oer
*lant.
Condenser cooling ater system is a once t3roug3 system 3en
sea ater is used for cooling. )3is is t3e most common *ractice in
t3e orld. 7oever river ater it3 cooling toers are also used in
inland *lants. >atural cooling toer and forced cooling toer are
to ty*es.
#earing lu4 oil( )ur4ine o*erating oil( lu4 oil( etc are cooled in a
tu4ular 3eat e6c3angers using a closed circuit cooling ater
system. )3is cooling ater is mostly ra ater used for ater
treatment *lant.

,#. What is the condensate -um-? What is the critical
-oint of =P&! for the -um- and how to handle it?
Condensate *um*s 3el* circulate ater (condensate) from Condenser
t3ru 5P 3eaters to De;aerator. >et Positive %uction 7ead (>P%7) is t3e
minimum 7ead (*ressure) re&uired at t3e suction of t3e Pum* to
function *ro*erly. )3e >P%7 can 4e maintained 4y a com4ination of
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t3e Pressure and t3e 5evel at t3e vessel from 3ic3 t3e *um* is ta/ing
its suction from.
,'. What is the function of De/aerator? What is the
o-erating -ressure?
De;aerator 3el*s in removing dissolved 12 in t3e condensate t3ere4y
*reventing *ossi4le corrosion inside t3e *i*elines. >ormally it is
maintained at Positive *ressure suKcient to maintain >P%7 for #,P at
all loads. >ormally( for 210 2 *lant(t3e Dearator ill 4e maintained
at 1.";;3." 4ars.
,). What are the feedwater heaters in the s"stem and
what is their function?
,eedater 3eaters are not3ing 4ut 3eat e6c3angers 4eteen #,P and
#oiler drum. )3ese 3eaters ill im*art 3eat to feed ater to *revent
large tem* diGerential 4eteen ater in 4oiler drum and t3e in;c*minf
feedater. 5arge tem* diGerence ould result in ater 3ammering.
t3ese 3eatersoving eKciecy of overall t3ermal cycle.
,,. What are the control ?nal elements used?
Control <alves (*nuematic( 7ydraulic and electric actuator)( Poer
cylinders( <aria4le s*eed controllers are t3e main :nal control
elements used.
,.. Assume that there is a load reduction in the *nit.
2he control s"stem has changed to manual. !ow "ou will
control1 $oiler %aster1 Drum Ae0el and &team
2em-erature control?
#oiler 2aster
C3ec/8adFust #oiler 2aster demand *ro*ortional to t3e steam fo.
Drum 5evel
C3ec/8adFust ,eed ater fo nearest to t3e steam fo.
%team )em*erature
C3ec/8adFust su*er 3eater inlet tem* nearest to t3at corres*onds
to steam fo.
,4. What is @e/heater? !ow to control re/heat outlet
steam tem-erature?
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In large 4oilers( to increase t3e eKciency( t3e steam from t3e 7P
cylinderr outlet ill 4e ta/en to t3e 4oiler again and *assed t3roug3
t3e set of 3eating coils and used at t3e 2P cylinder. )3is 3eating coil is
/non as re;3eater.
In a all :red 4oiler t3e fue gas from @co;inlet ill 4e *um*ed t3roug3
a fan to t3e furnace. )3is is /non as gas re;circulation. )3is ay t3e
fue gas mass ill 4e more t3an t3e steam fo. )3is ill 3el* to
increase t3e tem*erature *ic/u* in t3e re;3eater. In t3is case t3e re;
3eater *ic/u* may 4e mainly 4y convection.
%ome times fue gas ill 4e 4y*assed over t3e re;3eater.
In a corner :red 4oiler( 4urners ill 4e tilted u* or don to control re;
3eat tem*erature. In t3is case t3e @Gective ProFected 9adiant %urface
(@P9%) of t3e re;3eater is c3anged. In t3is ty*e of arrangement( re;
3eater coils are in suc3 a ay t3at t3e eGective 3eat *ic/u* is 4y
radiation.
)o met3ods are in *ractice? 9e3eat %*ray control( #urner tilt8#y*ass
dam*er8=as re;circulation control systems.
.7. !ow to +now re0erse ;ow in the case of 3@ :an and
how to handle it?
A reverse fo of fue gas in t3e =9 system ill *roduce 3ig3
tem*erature at t3e outlet of =9 duct after t3e fan.
A s3ut of dam*er as close as *ossi4le at t3e inlet to furnace ill
sto* t3e reverse fo. 7oever during o*eration of =9 fan a
*ositive feed4ac/ from t3e s3aft of fan end ill ensure no reverse
fo in t3e =9 system. )3is is a must 3en 3ydraulic cou*ling or
e&uivalent met3ods are used to control t3e s*eed of t3e fan.
.1. Whether the drum le0el between left and right will
be same on load? If di9erent what is the reason?
)3ere ill some diGerences 4eteen 5eft and 9ig3t side Drum level
measurements *rimarily due to un4alanced eva*oration 4eteen side
alls. )3is is caused 4y s3ift in :re 4all in a corner :red 4oiler or
un4alance :ring of 4urners it3 res*ect to drum center. It can 4e to
t3e e6tend of "0 mm.
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.2. Whether the drum le0el between the transmitter1
direct le0el gauge and electronic le0el monitors will be
same on load? If no1 what is the reason and how the le0el
will be indicating?
)3e DP transmitter measures t3e diGerence of force ( due to *ressure
C mass of t3e li&uid8steam) a**lied at t3e to *orts. B3en used to
measure level( t3e same s3all 4e corrected for any c3ange of Density
of t3e li&uid in t3e legs. B3en drum level is measured it3 DP
transmitter( t3e density of ater and steam in one *ort and t3e
reference coloumn ater are a**lied deriving from drum *ressure.
)3is is a real time correction a**lied from 0 to rated *ressure of t3e
4oiler. 7ence t3e level indicated 4y t3e transmitter ill 4e nearer to
t3e actual in t3e drum for all load.
7oever( direct level guages and electronic level monitors (li/e
7ydarste*) do not *rovide t3is correction. )3e ater in t3e measuring
vessel ill 4e less t3atn t3at of drum. )y*ically t3e tem*erature of t3e
drum ill 4e 3!0 Deg.C and t3e level gauge ill 4e 1"0 Deg.C. )3e
density of drum ater ill 4e 0.$ and t3at in t3e level coloumn ill 4e
arround 0.+. )3is is /non su4; cooling. )3is ill cause a considera4le
diGerence in t3e level 4eteen t3e DP transmitter and t3e direct level
gauge. It can 4e 120 mm for a 4oiler of 1+0 4ar drum *ressure.
2ounting8 insulation of measurement legs on 3ic3 t3ese devices are
mounted ill 3ave considera4le 4earing on measurements of Drum
level vis;a;vis actual level in t3e drum. )3e direct mounted devices ill
read alays loer level com*ared to com*ensated DP )ransmitter
measurement.
.. 2he distance between to- and bottom ta--ing in a
drum for le0el measurement using DP transmitter is
1277mm. 2here are )77 mm a-art from center of drum.
2he normal water le0el will be 2'7mm below the center
line. 2he s-an of the le0el indicator is -lus or minus 2'7
mm. What will be the calibration range of the d-
transmitter?
)3e minus *ressure from Drum minimum level to t3e constant column
vessel middle is ! mA.
Ie.( minus 1100 mm of BC5 I ! mA
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)3e minus *ressure from t3e drum ma6imum llevel to t3e contant
column vessel middle is 20 mA.
Ie. 2inus $00 mm BC5 I 20 mA.
.#. What is soot blower? What are the t"-es?
%oot 4loers are devices used to 4lo steam on ater alls to remove
car4on de*osits8soot. )o ty*es 9otary (Ball 4loers) and 5ong 9e;
tracta4le (furnace alls).
.'. Whether the blowing -ressure will be same for all
the blowers? !ow to set the blowing -ressure?
)3e 4loing steam *ressure for soot 4loers ill 4e diGerent
4eteen t3em. )3e 4loers for :nal su*er 3eater8re;3eater ill 4e
ma6imum. )3e *ressure de*ends on t3e tem*erature in t3at Aone.
Pressure at su*er 3eater Aone ill 4e 22 4ar( convection su*er
3eater Aone is 12 4ar( economiAer Aone is 10 4ar and it is + 4ar for
air 3eaters.
)3e soot 4loer steam ill 4e ta/en after *rimary su*er 3eater
4efore attem*arator . It ill 4e reduced to 2" 4ar. @ac3 soot 4loer
ill 4e *rovided it3 a valve. )3e lift of t3e valve can 4e adFusted
4y a nut. 7ence t3e *ressure after t3e valve(
t3e 4loing *ressure( can 4e adFusted as re&uires. )3rottling of t3e
valves s3all 4e avoided if *ossi4le.
,irst t3e soot 4loer far aay from t3e reducing station in su*er
3eater Aone s3all 4e selected. A *ressure gauge s3all 4e :6ed after
t3e valve. )3e valve s3all 4e left full o*en. Con:rm t3e 4loing
*ressure. AdFust t3e soot 4loer steam 3eader *ressure to get t3e
4loing *ressure of t3e soot 4loer.
2ove u*ard toards reducing station and set t3e 4loing
*ressure 4y t3rottling t3e valve. )3e tem*orary *ressure gauge
s3all 4e used for con:rmation.
9e;adFust t3e station if it is to 4e increased to get t3e 3ig3est
4loing *ressure and re*eat donard and set t3e *ressure 4u
adFusting t3e lift of t3e 4loer valve.
.). !ow to ?nd out the soot blower header -ressure?
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As e6*lained a4ove during( t3e ma6imum *ressure re&uired is t3e
3eader *ressure.
.,. What are the -arameters to be monitored when the"
are o-erated manuall"?
%# steam *ressure and steam tem*erature( )ime cycle and se&uence
of 4loers.
... What will ha--en if a soot blower is tri--ed on o0er
current during forward motion?
>ormally( if t3e %# motor tri*s in t3e forard *osition of 4loer( t3e
4loer can get damaged due to e6*osure to furnace 3eat. 7ence(
eit3er t3e 4loer 3as to 4e it3ddran using manual o*eration from
local.
.4. What are the reasons for high steam tem-erature at
the -rimar" su-er heater outlet? !ow to handle it?
)3e 3eat transfer in t3is Aone is *urely 4y convection. In t3is t3e
steam fo and mass fo of fue gas s3all 4e matc3ed. If t3e fue
gas mass is more t3an t3e steam fo( t3e steam tem*erature ill
increase. >o attem*erator is *ossi4le for t3is section. #y *ro*erly
adFusting t3e air fo for t3is lo load ill maintain t3e *rimary
su*er 3eater steam tem*erature it3in limits. B3en t3e Automatic
com4ustion is tuned( t3e fuel8air ratio s3all ta/e t3is into
consideration in :6ing t3e e6cess air.
Care s3all 4e ta/en during 2anual o*eration of ACC at lo loads.
47. What are the t"-e of control algorithms used?
Pro*ortional( Integral( Derivative are t3e t3ree algorit3m of feed;4ac/
control..
41. Wh" to maintain ) G , KgFcm2 d- across the feed
water control 0al0e?
>ormally in a 4oiler t3e s*ray ater ill 4e ta**ed of at t3e inlet of
,eed Bater Control valve. At full load t3e *ressure dro* 4eteen
t3e ta**ing *oint and t3e attem*erator noAAle ill 4e 10 4ar
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it3out any *ressure dro* across t3e ,BC<. 1n minimum au6iliary
*oer consum*tion *oint( t3is is ideal o*erating condition. )3e
4oiler feed *um* s*eed ill 4e modulated to *rovide t3e &uantity
of feed ater fo to drum.
)3e 10 4ar d* across t3e s*ray control valve is enoug3 to *rovide
t3e re&uired s*ray ater fo.
At "0E t3e d* across t3e s*ray ater control valve( it3 same 0 d*
across ,BC<( ill 4e 2." 4ar. )3is d* ill not 4e enoug3 to *rovide
t3e s*ray fo. 2ore over t3e &uantity of s*ray at "0E ill 4e
ma6imum and t3at at full load ill 4e minimum.
)3e re&uired d* across )C< can 4e *rovided 4y maintaining a
minimum d* across t3e ,BC<. 7ence in Drum 5evel control loo*(
t3e feed ater fo is controlled 4y 5C and t3e d* across ,BC< is
controlled 4y t3e #,PPs s*eed control.
)3e steam tem*erature control is a case cade loo*. )3e secondary
ill control after attem*eraor tem*erature. Assume t3at s*ray
ater re&uired to reduce 1 Deg.C at full load is 1 )87. )3e s*ray
ater demand at "0E load to 1 Deg.C. ill 4e 0." )87. If t3e d*
across t3e )C< is maintained constant( a @&ual E valve ill *rovide
satisfactory results in t3is a**lication.
If t3e d* across t3e ,BC< is controlled constant at ' 4ar from "0E
to 100E( t3e d* across )C< ill 4e -." 4ar at "0E load and at
100E load it ill 4e 1' 4ar. In t3is case an ada*tive gain s3all 4e
a**lied .
)3e d* across )C< can 4e maintained constant at 1' 4ar 4y setting
t3e ,BC< d* at 1!." 4ar at "0E and ' 4ar at 100E.
42. What is the meaning of leadFlag control with res-ect
to $oiler %aster? What is cross limit and cross bias?
)3e #oiler 2aster Controller controls #oiler outlet %team *ressure 4y
regulating ,uel (Coal81il8=as) and Air re&uired for com4ustion. ,or any
com4ustion to 4e eGective ( t3e volume of air re&uired 3as to 4e e&ual
to atleast t3e %c3iometric ratio. 7oever( it is necessary to *revent
,uel ric3 conditions in t3e 4olier as it can lead to un4urnt car4on and
un;controlled com4ustion resulting in *ossi4le e6*losion. 7ence( t3e
control system design s3all ensure an air ric3 condition alays. to
accom*lis3 t3e same( 3enever t3ere is a demand to increase fuel(
t3e actual airfo s3all 4e increased :rst and t3en fuel fo (Air leads
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,uel). B3en t3e #oiler 2aster demands decrease in fuel fo( :rst fuel
3as to 4e reduced and t3en air fo (Air lags ,uel). )3e Cross limiting
circuit ensures t3e a4ove to 3a**en;;actual Airfo and ,uel fo
measurement s3all 4e used to cross limit increase8decrease (t3ru
2a682in selectors) to ensure air ric3 condition alays.
4. !ow to ensure air rich in the furnace?
)3ru cross limit circuits (5ead;5ag) as e6*lained a4ove.
4#. What will be o-eration logic for selection of
transmitter when redundant transmitters are used for
control?
B3en 4ot3 transmitters are 3ealt3y( o*erator can select any
transmitter or average value for control (on Auto).B3en one
transmitter fails( t3e control s3all c3angeover to t3e ot3er 3ealt3y
transmitter and t3e alarm (failure) status to 4e noti:ed to t3e
o*erator. B3en 4ot3 transmitters are faulty 19 t3ere is a deviation
4eteen t3e to transmitter readings (4eyond s*eci:ed margin)( t3e
control loo* s3all 4e forced to 2anual and ,ailure to 4e alarmed to
o*erator including forced manual status.
4'. What will be logic when the transmitter fails?
9efer a4ove. ,orce t3e controller to 2anual mode( if t3ere is no
redundancy.
4). !ow to ma+e sure the failure of transmitter?
,ailure of transmitter is determined t3ru signal out of range (a4ove
10$E (20.-$ mA) or 4elo ;$E(3.0! mA)) detection of DC% .
4,. What is $um-/less transfer and how to achie0e it?
Controllers can 4e on Cascade8Auto82anual 2odes. B3enever t3e
controller status is c3anged( t3e *rocess s3ould not e6*erience a
variation(#.2P). In order to ac3ieve t3is( t3e out*ut s3ould 4e 3eld in
its last value 4efore t3e c3ange in status and t3e out*ut 3as t3en to
4e varied as *er t3e conrol re&uirements. DiGerent R)rac/ingR
com*utations can 4e con:gured to ac3ieve t3e same(P<;%< trac/ etc.)(
so t3at t3e controller does not see a deviation during 2ode c3ange.
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4.. What is balance/less transfer and how to achie0e it?
)3is is e6*erienced in a controller 3ic3 is controlling more t3an one
secondary out*ut simultaneously. If one of t3e secondary o8*s is
sitc3ed to manual or fails( t3e remaining o8*s 3ave to 4e
adFusted(4alanced) automatically to attain t3e desired *arameters.
)3is action of automatic 4alancing of t3e active o8*s (in a multi o8*
controller) it3out e6*eriencing a 4um* is /non as #alance;less
transfer (ac3ieved t3ru slo ram*ing). )3e com4ination of Auto =ain
c3ange and )rac/ing tec3ni&ues are used to ac3ieve t3e same.
44. *nder what circumstances1 the boiler master out-ut
will hunt and what is the solution?
#oiler 2aster demand (P<?#olier outlet *ressure) ill 3unt 3en t3e
5oad demand controlled 4y tur4ine is varying (eg? e6cessivegrid
fre&uency variation). In suc3 circumstances( it is 4etter to sitc3 to
R)ur4ine ,ollo 2odeR. #oiler controls ill loo/ at 5oad <ariation and
)ur4ine controls ill maintain #oiler outlet *ressure.
177. When air limit fuel alarm will a--ear and how to
handle it?
During 5oad demand variations( if t3e airfo cannot 4e maintained as
*er t3e fuel demand (refer lead;lag control)( t3e fuel fo ill 4e
limited 4y actual airfo;;air limit fuel alarm. In suc3 a case( t3e load
demand (fuel fo demand) 3as to 4e reduced 19 additional air
fans(,D) 3ave to 4e started to increase air fo. Be s3ould also c3ec/
3ealt3iness of 16ygen analyAer as t3e error in its reading can give
rong airfo values for control.
171. !ow to -rotect the su-er heater from saturation
steam?
#y *roviding )em*erature limiting controls to t3e %et*oint of t3e
%econdary loo* in a %team )em*erature control.
172. When the gain of a control loo- will need to change?
B3en t3e res*onse of t3e Process is diGerent at diGerent conditions
(eg? 1il or Coal or =as :ring( 5oad increase or decrease( >o of 2ills in
o*eration( no of ,ans8Pum*s in o*eration etc) t3e control loo* gain
needs dynamic variation design.
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17. What is the meaning of load test and what is the use
of it in the
(ontrol s"stem?
1*eration of a *lant at various loads is /non as 5oad tests. )3e
*arameters used in ,unction generators( 3ic3 are load de*endent are
collected after 30 min at eac3 load. @6. 2B( %team ,lo( ,uel fo( Air
fo( 12 in fue gas( %7 out tem*erature( Attem*erator outlet
tem*erature( #urner tilt8=r fan vane *osition( etc are t3e minimum to
4e collected. 2ain *ur*ose of t3e test is to correct all ,S as *er t3e
*resent *lant conditions.
17#. !ow to con?rm the -erformance of control s"stem?
As a *art of Performance =uarantee( C&I contractor is e6*ected to
limit t3e deviations in critical *arameters it3in limits s*eci:ed (C8; E
age) 4ot3 for steady state and dynamic load variations (%te* and
9am*). #y *ro*er design of t3e control system including
feedforard8feed4ac/ signals and 4y correct tuning of control loo*s(
t3e *erformance of control system is esta4lis3ed in limiting t3e
deviations it3in limits.
17'. What is furnace -urge? Wh" 7I air ;ow? Wh" not
177I air ;ow?
Wh" ' %in?
,urnace Purge ould involve alloing some minimum &uantity of air to
fo t3ru t3e furnace (it3out fuel) for a s*eci:ed *eriod of time to
remove any un4urnt fuel. )3is activity is done every time 4oiler is
started 4y running Air fans and Draft fans as re&uired. It is e6*ected
t3at it3 30E airfo maintained for a *eriod of " min( t3e volume of
air is ade&uate for t3e furnace to 4e *urged com*letely of all t3e
un4urnt fuel t3at may 4e residual in t3e furnace during t3e *revious
:ring o*erations t3ere4y removing *ossi4le uncontrolled
ignition8e6*losion during ne6t :ring o*eration.)3e Purge cycle is
*erformed it3 furnace maintained under t3e design *ressure(draft)
conditions.
17). What is generator -urging?
During Poer generation( =enerators radiate enormous 3eat. 7ence
t3e =enerator casing needs to 4e cooled. 7ydrogen gas is used for
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:llling t3e =enerator casing as it is most eGective. 7oever( 72 ill
easily react it3 air (12) unless it is T-+E *ure. In order to ensure
t3at t3ere are no entra**ed air in t3e =en casing(t3e casing is :rst
*urged it3 >itrogen gas as >2 is an inert gas.%u4se&uently( t3e >2
gas is dis*laced it3 72 and *urity maintained T -+E.
17,. What is three element control in drum le0el control?
Wh" it is
necessar"?
Drum level is controlled using t3ree measurement *arameters;; %team
,lo( Bater ,lo and Drum level signals. During ra*id load c3anges(
t3e ater level in 4oiler drum sells or s3rin/s due to c3ange in Drum
*ressure. )3is ould result in erroneous reading in actual Drum level
measurements. 7ence level measurement alone ill not 4e ade&uate
for control *ur*oses. In order to control level eGectively( t3e control
loo* is designed to vary t3e ater into drum 4y 4alancing t3e %tem
fo (4oiler 1.)) and ,eed ater ,lo(4oiler I>).)3e controller signal
is corrected t3ru t3e actual Drum 5evel deviations to continuously
correct t3e steady state level variations.
17.. What is J0er/?ring and *nder/?ring? What
-arameter of the boiler
will be a9ected much? !ow to o0ercome?
B3en load is increased in a 4oiler( as a dynamic com*ensation( fuel
:red ill 4e more t3an t3at re&uired for steady state. )3is is called
over :ring. %imilarly 3en load is decreased in a 4oiler fuel :red
ill 4e less t3an t3at of steady state. )3is condition is under :ring.
)3e tem*erature *ic/;u* in t3e :nal su*er 3eater ill vary
considera4ly. )3e value of c3ange is *ro*ortional to t3e E of
mismatc3. )3e feed forard loo* in*ut s3all 4e com*ensated
suita4ly to over come t3e eGect of mismatc3.
174. When to use deri0ati0e control? When to use
d"namic com-ensation?
Derivative control action is designed 3en t3e *rocess varia4le 3as a
tendency to c3ange ra*idly. 7ence an en3anced and immediate
control action is needed it3 res*ect to rate of c3ange. It needs
careful a**lication as im*ro*er tuning may result in *rocess singing
out of control. Dynamic com*ensation action is designed to aid t3e
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control action( 4y t3e infuence of ot3er *arameters (not controller
P<)( 3ic3 may recognise t3e antici*ated variation of controlled
P<.)3e controller res*onse needed may re&uired to 4e varied under
diGerent conditions and 3ence ty*ically ,eedforard control conce*ts
are used for dynamic com*ensation.
117. !ow to o0er come the non/linear characteristic of a
control6s ?nal
element?
If t3e c3aracteristics of *rocess variations are linear .r.t valve
o*ening( 4ut t3e control valve c3aracteristics are non;linear( a suita4le
c3aracterisation curve can 4e designed at t3e ou*ut of controller to
overcome t3e non;linearity.
111. !ow to com-ensate the gain for multi-le dri0es for a
single -rocess
0alue?
B3en as single controller is designed to control multi*le control
elements in *arallel( de*ending on t3e num4er of t3e control elements
in o*eration( t3e controller demand (common) 3as to 4e varied for t3e
same *rocess deviation. )3is is ac3ieved 4y dynamically varying t3e
Controller =ain de*ending on t3e num4er of ou*uts active at any
given *oint of time (Dynamic =ain c3anger).
112. What is the meaning of %J(& D%ulti-le Jut-ut
(ontrol &"stemE and
where it shall be a--lied?
)3e control system 3ic3 control single P< using a *rocess PID
controller as 2aster and an au6iliary Integral controller as slave is
called 21C%.B3en t3e P< is controlled 4y more t3an 1 :nal element(
using 21C% ill *rovide automatic gain modi:cation for num4er of
A82 stations on Auto. Also *rovide facility to use ,eed ,orard loo* for
suc3 loo*. 1ne e6am*le is t3e ,urnace Pressure control using 2 6 $0E
ID ,ans. )3e ,, ill 4e from t3e ,D ,an inlet vane demand.
11. What is $oiler :ollow mode?
)3e Poer generation (5oad)( in a *oer *lant can 4e c3anged 4y
modulating governer valve. )3is ill cause a c3ange in steam fo in
turn a c3ange in steam *ressure.)3e #oiler 2aster ill c3ange t3e fuel
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demand from t3e %, as ,, and 4y deviation in *ressure as feed 4ac/.
)3is Process 3ere in t3e #oiler Pressure Control R,ollosR )ur4ine
5oad controller is /non as t3e R#oiler ,olloR mode of o*eration.
During #olier ,ollo mode( #oiler 2aster ill 4e on Auto (controlling
*ressure) and )ur4ine 2aster ill 4e on 2anual or local Auto
(controlling 2B).
11#. What is 2urbine :ollow mode?
)3e Poer generation (5oad)( in a *oer *lant can 4e c3anged 4y
c3anging t3e fuel8air demand manually. In t3is condition t3e )ur4ine
2aster ill control t3e steam *ressure.
)3is Process 3ere in t3e )= 2aster R,ollosR #oiler is /non as t3e
R)ur4ine ,olloR mode of o*eration. During )ur4ine ,ollo 2ode( )3e
#oiler 2aster ill 4e on 2anual and )ur4ine control ill 4e on Auto
(controlling t3rottle steam *ressure)
11'. What is (o/ordinate control mode?
In order to get t3e 1*timum res*onse of 4ot3 #oiler ,ollo and
)ur4ine ,ollo mode( as 3ig3er level control function called Co;
ordinated 2aster Control is designed.In t3is con:guration( C2C ill 4e
t3e main 5oad demand controller and ill *arallely sending demand
for fuel from 2BD as a feed forard signal to #oiler 2aster and t3e
2BD to t3e )ur4ine 2aster in a Co;ordinate manner. )3is 3el*s #olier
controls to ta/e corrective measures( even 4efore t3e P< is c3anged
and at t3e same time )ur4ine control to &uic/ly res*ond to load
variations utilising t3e stored enery in t3e 4olier. )3is mode is called
as 2B Control or Co;ordinated #oiler ,ollo 2ode 4y <enders.
%ometimes it is necessary to o*erate *lant in Co;ordinated )ur4ine
,ollo 2ode ( #2 ; control 2B and )2 ; control steam *ressure). )3is
mode 3el*s to over come t3e large time lag in 4oiler.
11). What is Aoad $loc+?
During C2C mode t3e demand is a**lied *arallel to #2 and )2. )3e
res*onse of 4oiler ill 4e slo 3en com*ared to tur4ine. )3is ill
create deviation in 4oiler loo*s( suc3 as ,uel fo controller( Air fo
controller( %team tem*erature controller( Drum level controller( etc. It
is not advisa4le to continue load c3ange it3 a 3ig3 deviation. )3e
ca3nge in load demand ill 4e 4loc/ed until t3e deviation 4ecome
less.5oad 4loc/ ill 4e a**lied for 5oad Increase and 5oad Decrease.
Alarm ill 4e initiated to alert t3e o*erator.
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11,. What is @undown?
During load ram*ing( t3e au6iliaries may not 4e a4le to meet t3e
re&uired load due to c3ange in 4oiler conditions( aging of au6iliaries(
etc. It is *racticed to reduce t3e load and C2C demand sloly to a
safe limit. )3is is /non as 9undon.
11.. What is @unbac+?
In a large units( t3e au6iliaries ill 4e s*lit to to of 2 6 $0E ca*acity.
)3is ill 3el* to *roduce atleast "0E load during any suc3 au6iliary.
5oss ,D,8ID, ill reduce air su**ly. 5oss of #,P ill reduce feed ater
su**ly. 5oss of 2ill ill reduce fuel su**ly. B3en a loss of au6iliary is
sensed t3e load s3all 4e reduced to 4elo "0E as &uic/ly as *ossi4le.
5oss of ,an needs 100E8min rate. )3is control is initiated logically.)3is
is called 9un4ac/. 9un4ac/ for ,D, can 4e ac3ieved successfully for
almost all t3e 4oilers. 7oever t3e unit can survive for loss of #,P only
in t3e case of assisted circulation 4oilers. 5oss of coal 2ill ill transfer
t3e coal fo control to 2anual.)3e unit ill go to )ur4ine follo 2ode
for 9un4ac/.
114. What is (onstant Pressure mode and &liding
Pressure mode?
5arge units ill 4e o*erated at reduced steam *ressure at loads less
t3an $0E from 2"E. )3e *ressure ill 4e maintained constant at rated
value from $0 to 100E load. )y*ically for a ""0 2B .nit( *ressure ill
4e 120 4ar at 2"E load and increased *ro*ortionally to 1$0 4ar u*to
$0E load. )3is mode of unit o*eration is /non as %liding8<aria4le
*ressure mode. )3e governer valve ill reamin at a :6ed value e6ce*t
for any emergency. ,rom $0E to 100E t3e *ressure ill 4e maintained
constant at 1$0 4ar 4y modulating t3e governer valve( it is called
constant *ressure mode.In sliding *ressure mode an a**recia4le
amount energy is saved in t3e #,P.
127. What are the characters of (ontrol 0al0e and gi0e
e<am-le of their
a--lication?
)3e ty*ical fo c3aracteristics of a control valve are 5inear( @&ual
*ercentage( Quic/ o*ening ty*e. )3e c3aracteristic of valve
de*ends of loo* sense( diGerential *ressure across t3e control valve
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etc. ,uel oil fo control ; Controller is 5inear c3aracteristic.
@rror at various valve o*ening( from 0 to 100E( demands same fo
c3ange.)3e DP across t3e control valve is 3ig3 at loa loads and
decrease it3 res*ect to load. 7ence t3e C< at lo loads s3all 4e small
com*ared to at 3ig3 loads. A @&ual *ercentage valve ill *rovide suc3
C<.
,uel 1il )em*erature Control ; Controller is non linear c3aracteristic.
@rror is tem*erature. %ame error at small valve o*ening re&uire less
fo. At 3ig3er valve o*en demands large fo. )3e mass of steam
re&uired for "0E fuel can only c3ange t3e tem*erature 4y "0E at
100E fuel fo. DP across t3e valve is constant. 7ence an @&ual E
valve can *erform 4etter. 7oever t3e valves c3aracterics can 4e
matc3ed it3 t3e *rocess using ada*ting gain in DC% using valve
*osition demand.
121. What are the fail/safe conditions of control 0al0es1
gi0e t"-ical
e<am-le?
,ail safe conditions of Control valves are ,ail;1*en and ,ail;Close
(De*ending on t3e end *osition reac3ed 4y control valve on loss of
control signal8air su**ly).>ormally ,ail o*en valves are used in
@mergency a**lications li/e 9ecirculation line or #y*ass lines (7P
4y*ass( 7eater 4y*ass etc). <alves used for fuel fo are fail close
ty*e.
122. What are the t"-es of Instrument air com-ressors?
What is loading
and unloading?
9eci*rocating and centrifugal ty*e. 5oading ; Com*ressor running it3
suction valve o*en. .nloading ; Com*ressor running it3 suction valve
closed( ideal running
12. What are the t"-e of -um-s and gi0e their t"-ical
e<am-le?
Positive dis*lacement( reci*rocating( centrifugal ty*e( etc. Positive
dis*lacement ty*e ; ,uel oil *um*s( 9eci*rocating )y*e ; C3emical
dosing *um*( Centrifugal ty*e ; ,eed ater *um* and ot3e general
servcie *um*s.
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12#. !ow to control -rocess ;ow for centrifugal -um-
and -ositi0e
dis-lacement -um-?
Centrifugal *um* ; 2odulating t3e disc3arge side valve.
Positive dis*lacement *um* ; 2odulating recirculation valve.
12'. !ow to control ;ow of fan?
#y modulating t3e inlet vane
12). What are the t"-es of fan? What is di9erence and
gi0e e<am-les for
their a--lication?
A6ial and 9adial fan. A6ial fan can *rovide large fo at lo 3ead. @6.
,D fan( Ignitor fan( ID ,an( etc 9adial ,an can *rovide less
&uantity at 3ig3 *ressure. PA fan( ,lame scanner cooling air fan( etc.
12,. !ow e<-ansions are managed in the ducts?
@6*ansion Foints (2etal( clot3(etc) it3 sliding su**orts
12.. !ow e<-ansions are handled in the -i-es?
#ends it3 sliding su**orts. %*ring loaded 3angers.
124. Wh" insulations are used? Wh" to insulate the gas
duct u- to
chimne"?
)o *rotect accidental 4urning of 3uman. )o reduce 3eat losses. Ducts
are insulated u* to c3imney( even t3oug3 t3ere is no reason of
3eatloss or *rotection( to maintain t3e tem*erature a4ove sul*3ur
de *oint and t3ere4y to reduce corrossion.
17. What are the com-ensations to be a--lied for ;ow
measurement
using d- transmitters? Wh" com-ensation is
necessar"?
Pressure and )em*erature com*ensations. )3e cali4ration data
*rovided 4y t3e manufacturer is 4ased on design *ressure and
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tem*erature of t3e fo sensor. DP is *ro*ortional to <elocity;s&uare.
<elocity is *ro*ortioan to <olume and volume in turn inversionally
*ro*ortional to density. 7ence a mass fo is determined using DP
measurement it is necessary to com*ensate for actual mass fo.
11. What is the meaning of -ressure com-ensation in
the case of drum
le0el measurement using d- transmitter? What
is the tem-erature
com-ensation for drum le0el measurement using
d- transmitter?
#ot3 are density com*ensations. %ince t3e drum steam is at saturation
condition( it is *ossi4le to get density of steam and ater using eit3er
*ressure or tem*erature.
12. !ow to install transmitters for gas1 steam and
water?
=as ; A4ove ta**ing *oint( %team ; Preference 4elo ta**ing *oint.
)a**ing s3all 4e at t3e side of t3e *i*e. ,or fo condensate *ot s3all
4e used. If need to install a4ove t3e ta**ing *oint( condensate loo*
s3all 4e *rovided. )3e distance s3all not 4e more t3an 10 2. Bater ;
#elo ta**ing *oint.
1. !ow to connect the le0er between a dam-er and the
actuator for
ma<imum utili>ation of the minimum tor5ue?
Dee* t3e dam*er at t3e middle. )3e 5evers in t3e dam*er and
actuator s3all 4e 3oriAontal and vertically in line.
1#. !ow to ta+e care of the di9erential e<-ansion
between boiler and fuel
oil -i-es?
#y 3ose connection.
1'. !ow to connect the ;e<ible hose for a
ad0anceFretract burner?
)o avoid tist during movement in and out( oil *i*e s3all 4e 4elo
4urner gun vertically in t3e same line .
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1). What is Eccentricit" and Di9erential e<-ansion of
turbine? !ow to
handle during o-eration?
@ccentricity ; It is de:ned as t3e out;of;centre e6cursion of t3e a6is
of rotation of t3e s3aft and is measured as t3e diameter of a locus
traced 4y t3e centre of t3e s3aft at t3e *oint of measurement.
)3e normal value is less t3an 30 micro meter. If 3ig3 eccentricity it3
no associated 4earing vi4rations( it is *ossi4le t3at t3e it is not
genuine.

DiGerential e6*ansion ; Due to 3ig3 steam tem*erature 4ot3 stator
and rotor of t3e tur4ine ill e6*and. )3e diGerence 4eteen t3e to
e6*ansion is diGerential e6*ansion. )3is s3all 4e as minimum as
*ossi4le. 1t3erise t3e ga* 4eteen t3em ill reduce and can cause
damage to t3e tur4ine 4lades.
.niform slo rise in tem*erature s3all 4e maintained. 9otor ill o4tain
t3e tem*erature &uic/ly. #ut t3e stator ill ta/e long time to o4tain
t3e actual steam tem*erature.
1,. E<-lain on line 0al0e testing of a turbine?
)o con:rm t3at t3e governor valves and sto* valves ill closed fully
during emergency tri*( t3ey ill 4e tested during load o*eration. )3e
load ill 4e reduced to '0E and 4elo. 1ne valve at a time ill 4e
initiated to close. 5oad ill remain same. )3e ot3e valves ill o*en
and com*ensate t3e e6cess fo.
1.. What are the annual maintenance acti0ities of a
thermal -lant?
Annual maintenance activities of a t3ermal *lant ? ;
1ver 3auling of 4urners( drum internals( rotary e&ui*ments
%uc3 as ID( ,D( & PA ,ans (Pressure *arts suc3 as tu4e
9ecti:cation or/s& tu4e t3ic/ness survey ( ,lue gas duct
Ins*ection & re*air or/s ( etc.
1ver 3auling of ).9#I>@
78P & 58P <alves( #,PPs and its feed ater lines( etc.(
9e*lacement of insulation.
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14. What are the au<iliar" -lants in a -ower -lant?
D2 Bater )reatment Plant( As3 7andling *lant( Baste Bater treatment
*lant( Instrument air and %ervice air *lant( 7ydroAen *lant( =as
c3lorination *lant( @lectro 3y*oc3loride *lant( CB *lant( etc.
1#7. What are the functions of D% Water -lant?
%torage of ra ater( :ltering( an;ion and cation treatment( 4ac/
as3 of ion e6c3angers( storage of D2 ater.
1#1. What are the materials of the 0arious com-onent of
the boiler?
Drum( don comer and ater all tu4es( economiAer tu4e( 7eaders ;
Car4on steel Primary and *art of :nal su*er
3eater ; 5o cromium alloy steel( )11
@6it coils of :nal su*er 3eater ; 7ig3 cromium alloy steel( )22
Ducts ; 2ild steel
#oiler tu4es ; Bater all tu4es I Car4on steel %A210 =r. C(
%CB ; Car4on steel %A 210 =r. C ( @co. )u4e ;%A210 =r. A1.(
5)%7 tu4es ; %A 20-=r. )1.( %A 213 =r. )11.( %7 tu4es ;;;;
%A 213 =r. )22.( 7eaders I alloy steel.( #urners ; Coal noAAle I
Cast steel. ( Coal ti* I %.%.310.
1#2. What is the allowable rate of increase and decrease
of -ressure and
load?
)3e main criteria is saturation tem*erature of ater in t3e drum. 2a6
+0 Deg.C87our for increasing t3e load. "$ Deg.C87our for decreasing.
,or some 4oiler 3ere t3e drum metal is also alloy steel it3
<anadium( t3e diGerence of metal tem*erature 4eteen 4ottom and
to* s3all not 4e more t3an "0 Deg.C
1#. What is silica -urging?
B3en a 4oiler is started after s3ut don( t3e silica in drum ater ill
4e 3ig3. )3e alloance of silica is matter de*ending on *ressure.
During startu*( t3e *ressure ill 4e maintained at t3e alloa4le lo
value and ater all and drum 4lo dons ili 4e o*erated. )3is
*rocess ill continue at various *ressure. )3e aim is to run t3e 4oiler
at lo silica for t3e *ressure. )3is o*eration is called %ilica Purging.
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1##. !ow to charge steam in a -i-eFheader?
)3e drains and vents s3all 4e left o*en. %team s3all 4e admitted at
lo rate until continuous steam fo is o4served in t3e vents and
drains. )3e steam admittance s3all 4e increased simultaneously
closing t3e vents and drains.
1#'. In which condition1 $:P can be started with
discharge 0al0e full"
o-en and scoo- in rated -osition? What will be
the changes in the
starting current and is the design criteria on the
motor?
During Auto staring in %tand4y mode. %tarting current ill 4e same.
)3e starting time illing 4e more and settling current ill 4e more and
e&ual to t3e load current. )3e motor s3all 4e designed to it3
standing t3e 3eating during t3is start u* on load. )3ermal relay s3all
4e set 4y t3is 3ea&t loss.
1#). !ow to change o0er :JP during boiler in ser0ice?
%tart t3e stand4y *um*. Con:rm t3e current of t3is *um*. %to* t3e
runing *um* immediately.
1#,. What is atomi>ing of fuel oil? !ow man" t"-e of
atomi>ing are in
-racticeU
2a/e a s*ray of :ne *article is called AtomiAing of fuel. 2ec3anical
and Assisted atomiAing. Air and steam are t3e medium used for
atomiAing t3e fuel.
1#.. What is turn down ratio of a burner?
)3e ratio of full ca*acity to t3e loest ca*acity of fuel t3at can 4e :red
in a 4urney it3 safety and a siAe t3an can 4e detected 4y t3e
scanner is /non as )urn Don of a 4urner.
1#4. What are the com-onents of a :uel Jil $urner?
Distri4utor( mi6er and s*ray *late.
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1'7. !ow man" t"-es of :J burners with regards to
mi<ing of fuel and
atomi>ing medium are in -ractice? What will be
relation between the
fuel Jil and Atomi>ing medium -ressure for the
di9erent t"-e of
mi<ing?
)o ty*es. @6ternal mi6ing and Internal mi6ing. @6ternal mi6ing ;
AtomiAing medium *ressure ill 4e constant from lo load to full load
of t3e 4urner. @Kciency of com4ustion is moderate. @asy to o*erate
and control. Internal mi6ing ; AtomiAing medium *ressure ill 4e
alays 1 to 1." 4ar 3ig3er t3an fuel oil. )3e diGential *ressure s3all 4e
maintained. Com4ustion eKciency is good. DiKcult to o*erate in
manual.
1'1. What is %ulti-le feedforward and in which loo- it is
used?
B3en a feed forard signal 3as an e&uation yOm6( t3e correction 4y
PID s3all 4e a multi*lier. )3e 0 ;100E s3all 4e converted to 0 to 2.
1t3erise t3e conventional feed forard ill *roduce a rong out*ut
and t3e PID 3as to correct t3e out*ut for every load. @6am*le is #oiler
2aster. B3en steam fo is 0 t3e out*ut s3all 4e 0. #ut conventional
,, loo* ill *roduce an out*ut e&ual to PID out*ut.
1'2. !ow to decide the tem-erature of :uel Jil heating?
,uel oil around 1" C.% is suita4le for atomiAing and 4urning in 4urner.
@very oil 3as its viscosity. A c3aracteristic 4eteen )em* and viscosity
ill 4e *rovided 4y t3e fuel oil su**lier. )3e tem*erature of oil 3eating
is t3at ill ma/e oil viscosity e&ual to 1" C.%.
1'. What t"-e of 0al0e characteristic is suitable for :uel
Jil !eating with
steam? !ow to com-ensate the control gain in
case of Ainear 0al0e?
An @&ual *ercentage valve is suita4le for oil 3eating it3 steam
control valve. )3e gain s3all 4e multi*lied
(measured oil fo8rated oil fo)
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1'#. !ow to com-ensate the e9ect of swell and shrin+ in
the drum during
load change?
During incrase of steam fo( t3e level in t3e drum ill raise due to
decrease in density. )3is is /non %elling. %imilarly during decrease
in steam fo( t3e level ill reduce due to increase of density. )3is is
%3rin/ing. A d8dt of steam fo it3 a time constant of 30 to !" sec
and gain of 0.2 ill *rovide re&uired com*ensation for t3e a4ove
eGect.
1''. What are the t"-e of ;ame scanner? What t"-e is
suitable for :uel oil1
=atural 3as1 AP3 and (oal?
<isual ,lic/er( I9( .<( etc are some of t3e fame scanners availa4le in
t3e mar/et. ,uel 1il ; <,
>atural =as ; .<
Coal ; <,
1'). !ow much steam can be -roduced for a ton of :uel
Jil of !!8
171777KcalF+g?
Around 1' ) of steam can 4e *roduced for a)on of ,uel 1il.
1',. What is e<cess air in a boiler? Wh" it is necessar"?
!ow much it will
be in the case of (oal1 :uel Jil and 3as?
)3e air su**lied a4ove t3e )3eoretical air r&uired for com4ustion is
@6cess Air. @6cess Air I E O ()otal air; )3eoetical
air)8)3eoretical air. Coal ;
2" to 30E
,uel 1il ; " ; 1"E
=as ; " to 10E
1'.. !ow to measure e<cess air?
#y measuring t3e e6cess 16ygen in t3e fue gas.
@6cess air E O 12821 S 100
1'4. What is the range of correction b" J2 control?
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0.+ )1 1.2
1)7. What is combustion?
Com4ustion is t3e *rocess of 3ig3 s*eed o6idation. And converting t3e
Car4on and 7ydro car4on in a fuel it3 ignition energy in to C12 is
called com4ustion. )3e 3eat of reaction /ee*s t3e un4urned *art of
t3e fuel in t3e fame Aone. Be 4urn coal( ood or gasoline( e really
4urn gas *roduced from t3ose solid or li&uid.
1)1. What is :lame -ro-agation 0elocit"?
)3e ignition energy from a fame ill 4e transferred to t3e fuel
adFacent. )3e energy *ro*agation from middle of a fame to t3e root of
t3e fuel admission is t3e *ro*agation velocity. )3is is *ro*ortional to
t3e volatile matter ( C7 com*onent) in t3e fuel. )3e a6ial com*onent
of secondary air and fame *ro*agation velocity s3all 4e adFusted suc3
t3at *ro*agation s3all sto* around 300 mm from t3e root of t3e
4urner.
1)2. What is the e9ect of modulation of air register in a
wall ?red
burner?
Irres*ective of t3e *osition of air register( t3e air fo ill 4e e&ually
distri4uted 4eteen 4urners if all t3e air registers ere at t3e same
*osition. Closing of A9 ill increase t3e angle of incidence. )3is ill
increase t3e diGerential *ressure 4eteen ind;4o6 and furnace. )3e
vertical com*enent ill 4e more and a6ial com*onent ill 4e less. )3is
ill 4ring t3e fame toards t3e 4urner and increase t3e sirrle
num4er. 1*ening of A9 ill *roduce o**osite eGect. ,lame ill 4e
longer and aay from t3e 4urner.
1). What do "ellow and blue ;ame indicates?
Vello fame ; 2ore car4on com4ustion( #lue fame ; 2ore 3ydro
car4on ( valatile matter) com4ustion
1)#. !ow are soot and smo+e formed?
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%oot ; de*osit of un4urned car4on( %mo/e ; uncom*leted com4ustion(
more C1 content
1)'. What is the e9ect of soot on the heating surface?
%oot ill reduce t3e 3eat transfer to t3e foing medium
1)). Which will increase tube metal tem-erature1 soot or
scale?
%cale ill increase t3e metal tem*erature
1),. What are commercial fuels?
Coal( ,uel oil and >atural gas
1).. What are the function of burner and furnace?
#urner is t3e e&ui*ment 3ic3 mi6 air to t3e fuel and s*ray t3e fuel to
t3e fame. ,urnace *rovides necessary volume for t3e fuel and air to
mi6 and 4urn.
1)4. !ow are soot and smo+e -re0ented?
Pro*er mi6ing of air. @noug3 air su**ly. %*liting t3e fuel to t3e :nest
level. 9etaining t3e fuel in t3e fame Aone to enoug3 *eriod of time.
=ood comnustion de*ends on )3ree )Ps( )em*erature( )ime and
)urr4ulance.
1,7. What are the -rinci-le com-onents of fuel used b"
-ower engineers?
Car4on( 7ydrogen( 16ygen( nitrogen( sulfer.
1,1. What is the a0erage heat 0alue of :uel Jil and 3as?
10(000 Dcal8Dg( 10(000 Dcal8D>23
1,2. What are the combustible elements in fuels?
Car4on and 7ydro car4ons ( C7n)
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1,. What element in the fuel is harmful to metal?
%ul*3ur
1,#. What are the -roducts of the com-lete combustion
of (arbon1
!"dro>en and &ulfur?
C12( 721 and %12
1,'. What are the -roducts of incom-lete combustion of
(arbon1
and &ulfur?
C1 and %1 are t3e *roducts of incom*lete com4ustion.
1,). What are the terminolog" used in ?ring fuels?
AtomiAing( secondary air( *ulveriAed fuel( etc. are some of t3e
terminology used in :ring fuel.
1,,. !ow does -ul0eri>ed fuel burned in the furnace?
PulveriAed coal is one t3at ground to :ne *oder 4efore 4eing fed
into t3e furnace.
PulveriAed fuel is carried 4y air and s*rayed t3roug3 4urner8noAAle
into furnace. )3e fuel is ignited 4y any ot3er fame( Igniter8oil
4urner in t3e 4eginning. )3e furnace tem*erature s3all 4e raised
a4out 2"0 Deg.C 4efore admitting PulveriAed coal (PC).
)3e *rimary air( secondary air and tertiary air s3all 4e adFusted to
ma/e t3e ignition at 200 to 300 mm from 4urner. %econdary air is
s*ined to *rovide mi6ing and to increase t3e stay time of t3e fuel in
t3e fame Aone.
1,.. E<-lain :lash -oint and the grades of oil?
,las3 *oint is a**lica4le for fuel oil. ,uel oil ill easily get ignited at
a 3ig3er tem*erature. )3is condition is /non as ,las3 Point for t3e
fuel oil.
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Diesel oil( #un/er IC oil( 5o sul*3ur 7ig3 stro/e oil( etc. are some
grade of fuel oil fued in 4oiler.
1,4. Is ?re -oint im-ortant?
)3e tem*erature( at 3ic3 oil start :ring( is :ring *oint. It is
im*ortant to 4urn a fuel.
1.7. Wh" do -lant o-erators +now about -our -oint of
their oil?
)3e *our *oint is t3e tem*erature of t3e fuel ill start fo 3en it
is *um*ed. )3e fuel in t3e *i*e s3all 4e /e*t at a tem*erature
a4ove *our *oint 4y 3eat tracing *rovided for t3e *i*es( :ttings and
t3e *um*s. 1*erator s3all adFust t3e set *oint de*ending on t3e
*our *oint of t3e fuel. B3en fuel oil is im*orted from diGerent
countries( t3e same ill vary consignment to consignment.
1.1. What is lea+ test and how to carr" out lea+ test?
5ea/ test in t3is &uestion is referring to t3e test in #2%. 1t3er lea/
test( air lea/ test ill 4e conducted for t3e furnace after com*letion
of construction. )3e furnace ill 4e isolated 4y t3e dam*ers and a
smo/e 4om4 ill 4e e6*loded inside t3e furnace. C3ec/ for any
lea/age of smo/e around furnace.
)3e lea/ test in #2% ill 4e conducted every time 4efore :ring. )3e
4urner isolating valves and long re;circulation valve ill 4e closed.
,uel ill 4e c3arged using a small ca*acity valve /non as c3arge
valve. )3e c3arge valve ill /ee* o*en for 2 min. )3en it ill 4e
closed. )3e DP across t3e )ri* ill 4e monitored after 2 min. If d* is
3ig3er t3an t3e *reset value t3en it ill 4e considered ,ail.
1t3erise it is successful. A successful com*letion of lea/ test ill
*ermit8initiate furnace *urge.

1.2. What is cold Bunction com-ensation in the
measurement of
tem-erature using thermocou-le?
)3ermocou*le is or/ing on t3e *rinci*le t3at t3e m< develo*ed
4eteen t3e to Functions of dis;similar metal is *ro*ortional to t3e
tem*erature diGerence 4eteen te Functions. 1ne Function ill 4e
*laced at t3e un/non Aone and t3e ot3er Function ill 4e made in
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a /non tem*erature( normally at atmos*3eric tem*erature. )3e
measure tem*erature is determined from t3e ta4le for t3e metals.
)3e /non tem*erature( 3ic3 is cold Function s3all 4e added to
t3e measured tem*erature to get t3e un/non tem*erature. )3is
calculation is cold Function com*ensation it3 res*ect to
t3ermocou*le.

1.. What is com-ensating cable in the tem-erature
measurement using
2hermo/cou-le?
<ery often t3e cold Function ill 4e made at t3e control room. )3e
t3ermo;cou*le ill 4e e6tended using ca4le of same metal 4efore
connected to co**er ire. )3is ca4le is /non as com*ensating
ca4le.
1.#. What is saturated steam?
)3e steam in raiser and drum is a mi6ture of ater and steam. )3is
is saturated steam.
1.'. What is su-er heated steam and wh" is steam
su-erheated?
)3e dry steam 3ose tem*erature is more t3an saturation
tem*erature is su*er 3eated steam. #y su*er 3eating t3e steam
more energy is added to t3e steam. 5ess mass of steam is
trans*orted from 4oiler to tur4ine. 9educe t3e siAe of *i*e and
:ttings.
1.). What would be the e9ect of sudden rise or dro- in
-ressure in a
header and boiler?
%udden rise ad dro* of *ressure ill c3ange t3e tem*erature. )3is
tem*erature diGerence 4eteen inside and out side 3eader and
drum ill create uneven stress and crac/.
1.,. (om-are the use of steam for -ower and for
heating?
%u*er 3eated steam is good for *oer generation. %aturated steam
is 4etter for 3eating.
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1... What are the critical tem-erature and -ressure for
steam?
$00 Deg.C and 22" 4ar.
1.4. !ow are steam boiler rated?
#oilers are rated 4y Pressure( )em*erature and ca*acity.
147. What are the e9ects of im-ure feed water in
boilers?
Im*ure feed ater leave scale in su*er 3eater tu4es. %ilica carried 4y
steam ill de*osit on t3e tur4ine 4lades.
141. B3at are t3e common im*urities in #oiler feed aterU
%alts of %odium( car4on and %ilica are some of t3e common
im*urities in feed ater.
142. What are the chemical methods of treating the
boiler feed water?
2ainly feed ater is treated in ater treatment *lant 4y *assing
t3roug3 an ion and cation e6c3angers. It is tried to maintain P7 of
t3e ater around - to -."
14. What are the Jn Aine chemical dosing for a boiler?
What are the
res-ecti0e E9ects?
Ammonia *3os*3ate is used to reduce acidity of feed ater.
7ydroAen is added to remove any dissolved o6ygen.
14#. What dangers ma" arise from oil -assing in to the
$oiler with feed
water?
1il in feed ater increases t3e ris/ of tu4e corrosion. 1ver 3eating
and su4se&uent damage is attri4uted to slugs of emulsi:ed oil.
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14'. Describe an a--aratus for remo0ing air and other
dissol0ed gases
from boiler feed water.
De;aerator
14). What is boiler -reser0ation?
B3en a 4oiler is used in service more t3an a ee/( t3e inside of t3e
tu4es ill 4e attac/ed 4y 16ygen in t3e air. 9ust may form. )o avoid
t3is 4oiler s3all 4e /e*t in suita4le condition. )3is *rocess is /non
as *reservation.
)3ere are to ty*es of *reservation met3ods are in *ractice.
)3ey are Bet and Dry met3od.
In 4ot3 cases t3e drum and ater all tu4es are *rotected 4y feed
ater mi6ed it3 200 **m of ammonia *3os*3ate and 200 **m of
7ydroAen.
%ometimes su*er 3eater tu4es also :lled it3 t3e a4ove mi6ture.
)3is is not advisa4le if t3e su*er 3eater is not draina4le.
In dry met3od( t3e 4oiler ill 4e :lled it3 t3e a4ove mi6ture u* to
W of drum. )3e remaining volume and t3e su*er 3eater tu4es are
:lled it3 >itrogen at 0." /g8cm2.

14,. Wh" should bare surfaces be insulated?
a. )o *rotect 3uman from accidental contact it3 t3e 3ot 4oiler
surface
4. )o avoid 3eat loss
c. )o maintain t3e metal a4ove sul*3ur de *oint and reduce
corrosion from sul*3uric acid condensed from fue gas.
14.. What are some insulating materials?

a. 3lass wool
b. Asbestos
c. (alcium silicate
144. What are the t"-es of 0al0es used in a boiler? 3i0e
e<am-le for each
0al0eM
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a. 3ate 0al0e / &to- 0al0es at the high -ressure steam
and water -i-es
b. Parallel slide 0al0e / &to- 0al0es at the high -ressure
steam and water -i-es
c. 3lobe 0ale / @egulating 0al0es
d. $utter ;" 0al0e / @egulating 0al0e
e. %ult" stage 0al0e / Pressure reducing 0al0e
f. $all 0al0e / 2ight shut o9 0al0es

277. What is the meaning of @e/!eat -roduction?
9e;3eater tu4es are fed from feeding steam of 7P cylinder of t3e
tur4ine. During start;u* for until rolling tur4ine( no steam ill 4e
availa4le for re;3eater. )3e metal tem*erature s3all 4e /e*t 4elo
"!0 Deg.C. A t3ermocou*le ill 4e inserted 4elo re;3eater coils
and t3e furnace tem*erature ill 4e monitored and controlled 4y
slo :ring rate. If t3e tem*erature goes more t3an t3e set value
and remain for more t3an fe minutes( 2aster ,uel )ri* ill 4e
initiated. )3is is t3e re;3eater *rotection during start;u*.
%ome *lants are *rovided it3 7P85P 4y;*ass system. ,lo t3roug3
re;3eater ill 4e esta4lis3ed 3en t3e *ressure is more t3an 20 4ar.
>o 2,) is initiated as long as fo is esta4lis3ed.
7oever 3en t3e tur4ine is tri**ed and t3e 7P85P 4y;*ass is not
o*en( after a fe secs 2,) ill 4e initiated as re;3eater *rotection..
271. What is !P/AP b"e -ass s"stem? What is the
-ur-ose of this s"stem?
%team around t3e tur4ine can 4e 4y;*asses to condenser. )3ey are
actually reducing station and de;su*er3eating stations. )3e main
steam is reduced to cold re;3eat *ressure and attem*erated to t3e
cold re;3eat tem*erature. )3is steam is fed to re;3eater. )3e steam
from 3ot re;3eat is reduced to 5P cylindersP e63aust *ressure and
t3e tem*erature is also reduced 4elo 1+0 Deg.C and admitted to
condenser.
)3is system of 4y;*assing 7P cylinder and 2P85P cylinder is 7P;5P
4y;*ass system.
272. What is balance draft?
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>ormally for solid fuel :red 4oiler( to fans ill 4e *rovided to
3andle t3e air and fue gas. %ince t3e *ressure dro* ill 4e
considera4ly 3ig3( it is economical to *rovide a fan( forced draft
fan( to su**ly com4ustion and *rimary air. A second fan at t3e
outlet of dust collectors ill 4e *rovided to suc/ t3e fue gas from
furnace.
In t3is case t3e furnace *ressure ill 4e maintained around minus
10 to minus 2" mm.
)3is draft system is 4alanced draft 4oiler.
27. Where to a--l" -ressuri>ed furnace?
)3e *ressure dro* in air8fue gas system ill 4e around $00 mm at
ind;4o6 for oil8gas :red 4oilers. ,urnace *ressure ill 4e at !00 to
"00 mm. Present tec3nology is a4le to 3andle *ressuriAed furnace
4y *ro*er 4uc/;stays.
27#. What are the t"-es of -ul0eri>ers in -ractice?
#all; mill ; 5o s*eed 3eavy mill it3 iron
4alls only In;
direct :ring is *ossi4le
#all tu4e mill ; 5o s*eed 3eavy mill it3 iron 4alls.
%uita4le for
direct :ring
7ammer mill ; 2edium s*eed and less eig3t it3
3ammers and
4eating. Direct :ring
#ol mill ; 2edium s*eed and less eig3t
it3 9ollers and
#ol. Direct :ring
27'. What is air balance test for a -ul0eri>er?
A coal mill normally ill su**ly coal to ! 4urners. It is necessary to
set e&ual fo of coal to eac3 4urner.
At t3e e6it of classi:er( *rovision is *rovided to insert ori:ce *lates.
)3e longest coal *i*e to t3e furt3est 4urner ill not 3ave any
ori:ce. Air ill 4e admitted t3roug3 mill during commissioning.
Pitot tu4e is inserted in all t3e ! coal *i*es. )3e fo is measured 4y
monometer. 1ri:ces of diGerent siAe ill 4e introduced in t3e
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remaining 3 *i*es. )3e ori:ce siAe ill 4e adFusted to ac3ieve e&ual
fo t3roug3 all t3e ! coal *i*es. )3is is Air 4alance test for coal
*ulveriAer.

27). !ow to o0ercome -lugging of im-ulse line for
-ressure measurement
in the case of -ressuri>ed coal -ul0eri>er?
E<-lain the set u-? What
is the im-ortant indication for such s"stem?
)a/e;oG *i*e for *ressure measurement in a *ressuriAed mill or
furnace s3all 4e X Inc3. It s3all 4e :6ed at more t3an $0 deg
vertically. Im*ulse ta**ing of Y inc3 s3all 4e *rovided ate t3e sides
and at t3e to*.
Air at a *ressure of 1 to 1.2 4ar ill 4e admitted at t3e to* im*ulse
ta**ing. )3e measurement im*ulse lines s3all 4e ta/en from t3e
sides..
)3is arrangement of continuous air *urging s3all 4e used to over;
come *lugging of im*ulse lines.
A con:rmation of air fo s3all 4e made 4y a roto meter.
27,. What are the -ermissi0e for furnace -urge?
a. All #urner s3ut;oG valve Closed
4. )ri* valve Closed
c. #urner 7eader re;circulation8vent valves o*en
d. All #urner air dam*ers 1*en
e. ID,8,D, running
f. Air fo T 30 E Z !0E of rated value
g. 2aster ,uel )ri* (memory ) 1>
3. >o 2,) condition
i. Drum 5evel is normal
F. 5ea/ )est successfully com*leted
/. All ,lame %canners 7ealt3y
l. >o scanner sense fame
27.. What is %:2? What are the tri- commands of a
boiler?
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%:2 is abbre0iation of %aster :uel 2ri-. It is also +nown as
$oiler 2ri-. All fuel su--l"ing 8al0eFe5ui-ment will
closeFsto- during %:2. :urnace -urge c"cle will be armed.
%:2 can be reset onl" after successful com-letion of
furnace -urge.
a. Drum 5evel very lo
4. ,urnace *ressure very 3ig38very lo
c. Air fo Z 20E of rated value
d. ,uel *ressure very lo
e. )otal ,lame ,ailure
f. Partial ,lame ,ailure
g. 5oss of all fuel
274. What is -artial loss of ;ame?
In a all :red 4oiler 3en a fame scanner sense no fame( t3e
res*ective 4urner s3ut;oG valves are demanded to close. If t3ey are
failed to close after 10 sec. it is announced as Partial ,lame loss.
If t3e num4er 4urners are less t3an a num4er 3ic3 can cause
unsafe condition( 2,) ill 4e initiated. %ometimes a load factor less
t3en '"E is also A>Ded for 2,).
Conservatively some *lants are initiating 2,) for Partial ,lame loss
irres*ective of any condition of t3e 4oiler.
217. What is total ;ame failure? When it will be enabled?
In a all :red 4oiler( after esta4lis3ing any 4urner( if all scanner
sense no fame for 2 sec( it is announced as )otal fame failure and
ill cause 2,).
In a corner :red 4oiler( if 28! scanners in any level of 4urners sense
fame( t3en it is :re 4all is *roven. If no level sense :re 4all t3en it
is announced as )otal ,lame failure and ill cause 2,).
211. What is loss of all fuel? What is the -ur-ose of this
tri-? When it will
be enabled?
If an" burner shut/o9 0al0e is sensed not closed and all the
burner shut/o9 0al0es are -ro0en closed or tri- 0al0e is
closed it is +nown as Aoss of all fuel and will initiate %:2
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2his is enabled as soon as an" burner shut/o9 0al0e is
-ro0en not closed.
212. What is @eset wind/u-? What is the best wa" to
handle this in steam
tem-erature control?
In PID control1 if ste-s are ta+en1 the out -ut will go on
change b" Integral1 as long as the error e<ists. 2he ?nal
element will o-erate between 7/177I. $e"ond these limits1
there will not be an" change in -rocess. 2he out -ut of an"
control shall be sto--ed be"ond this limits for immediate
action when there is a change in the direction of error.
2he unlimited action of PID b" Integral is @est Wind/u-. An"
action ta+en to sto- this action is Anti/reset wind/u-.
In a :eedbac+ loo-1 as an Anti reset wind/u-1 the out -ut
will be limited to 7/177I
In a case cade loo-1 the Integral of Primar" shall be sto--ed
when there is no change in -rocess 0ariable of secondar"
loo-. 2he out -ut of the -rimar"shall be sum of the
secondar" P8 and the Pro-ortional com-onent of error of
Primar" loo-.
2he abo0e logic for reset wind/u- acts satisfactoril" for
&team 2em-erature (ontrol.
21. What are the t"-es of coal feeder? !ow to detect
the -lugging of inlet
chute for $oiler %aster control?
Conveyor ty*e and rotary ty*e are to main coal feeders used in
4oilers.
Conveyer ty*e is *rovided it3 eig3 4ridge. )3e fo ill 4e
availa4le for control.
B3en a rotary feeders are used t3e fo is calculated from
revolution of t3e feeder. )3is may 4e a misleading factor for some
conditions. )3e c3ange in #oiler 2aster out *ut more t3an t3at
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re&uired for t3e load ill *rovide a good indication of *lugging of
coal c3ute.
21#. What is the main cause for the 0ibration of a 0ertical
s-indle
-ul0eri>er?
Presence of stone1 iron -iece and similar foreign material
are the main cause for 0ibration for a 0ertical s-indle mill.
21'. Which is the most suitable -ul0eri>er for hard1 more
abrasi0e coal or
dirt" (oal storage area?
#all tu4e mill
21). !ow is air ;ow is measured in a small boiler? Wh" it
is must to
%easure the air ;ow after @otating air heater?
Air fo is measured at t3e inlet of fan. %ome times t3e d* across
tu4ular air 3eater is used for fo calculation.
A4out 10E of t3e air ill lea/ to fue gas in an rotary air 3eater.
)3is lea/ is also de*ends on air 3eater c3o/age( seal condition( etc.
)o ma/e certain t3e air fo for com4ustion( t3e actual fo after air
3eater s3all 4e measured.
Aerofoil is used for t3e measurement.
21,. What is the -rinci-le of the heat transfer to water
wall1 -rimar"
su-er heater1 -laten su-er heater?
Water wall / @adiation
Primar" su-er heater / (on0ection
Platen su-er heater / .7I @adiation1 27I
con0ection
21.. What is air balance test in a EP? What is the
-ur-ose?
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)o ac3ieve 4est results( t3e velocity of fue gas t3roug3 @%P s3all 4e
as minimum as *ossi4le( around 1 m8sec. A duct of large area is
*rovided for @%P. Due to aero dynamic t3e fo ill 4e uniform
t3roug3 out @%P.
A distri4ution *late is *rovided in t3e inlet of t3e @%P. It ill 3ave
uniform 3oles. Cold air ill 4e send t3roug3 @%P. <elocity ill 4e
measure 4eteen electrodes. #loc/ing *lates ill 4e used to close
certain 3oles in t3e distri4ution *lace to get an uniform velocity
across t3e @%P. )3is is air 4alance test of @%P.
It is to im*rove t3e eKciency.
)3e folloing are some of t3e causes for *oor *erformance of @%P?
a. @6cess gas volume
4. Poor gas distri4ution
c. )rac/ing and air lea/age
d. @lectrode 4rea/age
e. As3 resistivity
f. Particle siAe
g. @lectrical conditions
3. 1ver;full 3o**ers
i. Defective collector *lates

214. What will be the normal ;ame tem-erature for coal1
oil and gas?
Coal ; -"0 Deg.C
1il ; 10"0 Deg.C
=as ; 1200 Deg.C
227. What is the e9ect of high ;ame tem-erature in the
case of coal?
As3 ill melt and ma/e 3eavy slag on t3e ater all tu4es. Clic/ers
ill form in t3e furnace and cause trou4le to 4ottom as3 removal
system
221. What will be the ma<imum and minimum PA 0elocit"
in a -c -i-e?
2inimum velocity ; -0 m8sec
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2a6imum velocity ; 120 m8sec
222. What is EP@&? Wh" -ressure increases and
tem-erature reduces
ra-idl" during wall blower o-eration in a coal
?red boiler?
@Gective ProFected 9adiation %urface is a44reviated as @P9%.
%ome area of su*er 3eater( re;3eater( ater all( etc. are covered
4y ot3er tu4es( slag( etc. )3is ill cause reduction in surface area of
t3e 3eat e6c3anger 3ic3 is su4Fected to direct radiation from
fame. )3e area 3ic3 is su4Fected to direct radiation from fame is
@P9%.
B3en Ball 4loers are in service( t3e slag from ater all tu4e ill
reduce and @19% of ater all ill increase. )3is cause more 3eat
a4sor*tion 4y ater all and more steam eva*oration. )3is ill
increase steam *ressure.
1n t3e ot3er 3and( t3e 3eat transfer to su*er 3eater ill reduce.

22. When does Air heater ?re start?
)3e *ossi4ility is e6tremely remote on 4oilers o*erated
*redominantly on P, :ring at
Continuous 3ig3 loads. It is more li/ely during or after a 4oiler lig3t
oG on fuel oil( *articularly from cold or during *eriods of lengt3y
lo load o*eration during 3ic3 P, fames are sta4iliAed 4y fuel oil.

22#. What is full arc and -artial arc o-eration?
5arge siAe tur4ines ill 3ave multi*le governor valves for control.
2ost of t3em are it3 ! or + valves.
%team fo can 4e controlled 4y t3rottling all valves e&ually or in
s*lit mode.
B3en t3e valves are o*erated it3 e&ual *osition( it is on ,ull Arc
mode.
)3is mode is folloed during start;u* or continuous lo load
o*eration.
)3e %*lit range o*eration of governor valves is Partial Arc 2ode.
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)3is is mode for normal o*eration.

22'. What is Anti/-um- circuit in a latched contactor
control circuit?
UUUUU
22). What is the consideration to be a--lied for
installation of ori?ce in a
-i-e for ;ow measurement?
%traig3t lengt3 of *i*es s3all 4e *rovided at t3e don stream and
u* stream of ori:ce.
At least ! times t3e diameter at t3e in let and 10 times diameter at
t3e out let s3all 4e availa4le.
22,. What is scan time in a D(&? !ow to decide the scan
time?
In a DC% t3e in*ut and out*ut are monitored at intervals. )3e
calculation is *erformed from t3e in*ut data and out *ut are send
after calculations. )3e interval 4eteen t3ese o*erations is %can
time.
)3e scan time s3all 4e less t3an 183 of t3e *rocess dead time. <ery
fast scan ill not *rovide any 4etter result. ,or safety system ,ast
scan time of 10 msec may 4e considered. ,or *rocess *arameter a
scan time "00 msec is suKcient.
22.. What is the di9erence between D(& and PA(?
DC% I %can time ill 4e a4ove 100 msec.( Consists of 4loc/s for
regulatory controls. Dedicated 7uman 2ac3ine Interface
P5C ; %can time ill 4e less t3an 10 msec. Consists of less variety
of 4loc/s for regulatory control. Can 4e used it3 t3ird *arty
softare as 72I
224. What is &E@ D&E%E?
A *lant tri* ill initiate many tri* signals. It is necessary to :nd out
3at is t3e actual cause for t3e tri*. All events ill 4e /e*t in
system memory for " min. B3en a tri* occurs( t3e events 4efore "
mins after t3e tri* ill 4e dis*layed and also *rinted. )3is feature is
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%e&uence of @vents 9ecording (%@9) or %e&uence of @vents of
2onitoring (%@2).

27. !ow to handle instrumentation in a ha>ardous area?
a. Providing e6*losion *roof instruments of various safety level for
t3e location
4. .sing Intricically safety system. )3is system reduces t3e energy
level at t3e electrical contact in t3e :eld to a very minimum
value. %till *rovide monitoring to t3e control system.
21. What is the ( and I e5ui-ment housing classi?cation
according to
IE(?
Ingress Protection Codes in accordance it3 I@C $0 "2- I IP SS
Digi
t
,irst Digit
P3ysical Protection
,oreign 4ody
Protection
%econd Digit
Bater Protection
0 >o Protection >o Protection >o Protection
1 Protection against 4ac/
of 3and contact
Protection against
solid foreign 4odies
"0 mm dia
Protection against
ater dro*s falling
vertically
2 Protection against
:nger contact
Protection against
solid foreign 4odies
12." mm dia
Protection against
ater dro*s falling at
an angle (1" deg.)
3 Protection against
contact from tools
Protection against
solid foreign 4odies
2." mm dia
Protection against
ater s*ray at an angle
u* to $0 deg.
! Protection against
contact it3 a ire
Protection against
solid foreign 4odies
1.0 mm dia
Protection against
ater s*ray from all
directions.
" Protection against
contact it3 a ire
Protection against
dust
Protection against
ater Fets
$ Protection against
contact it3 a ire
Dust tig3t Protection against
strong ater Fet
' ; ; Protection against
intermittent immersion
in ater
+ ; ; Protection against
continuous immersion
in ater
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22. E<-lain 3land &team &"stem?
=land s are *rovided on 7P and IP tur4ines to reduce esca*e of
steam to minimum 3en t3e tur4ine s are on 3ig3 load and to
*revent t3e ingress of air into t3e tur4ines during start;u* or lo
load o*eration( 3en t3e *ressure is less t3an atmos*3ere.
5P tur4ine glands need only seal against air ingress as t3e cylinders
run under vacuum conditions at all loads 4ut( 3atever t3e
a**lication ( steam;*ac/ed la4yrint3;seal;ty*e glands are invaria4ly
em*loyed.
)3e stationary *art is divided into to or more sectors( eac3 of
3ic3 is s*ring Iloaded in and annular groove.
7P and IP cylinders usually em*loy relatively long glands divided
into sections( se*arated 4y *orts or *oc/ets.

2. What are the +inds of oil s"stem in use in a steam
turbine?
a. 5u4 oil system
4. Control oil system
c. Poer oil system
2#. What are the t"-es of 3o0erner controls?
a. 7ydraulic governor
4. @lectro;3ydraulic governor
c. Digital @lectronic 3ydraulic governor

2'. What is the -ur-ose of (ondenser?
)3e condensing system is sim*ly a 3eat;e6c3ange *rocess in 3ic3
steam from 5P tur4ine is condensed 4ac/ into ater to re;use in
4oiler
Quantity of 7eat loss is very large. It 3as a serious im*act on t3e
eKciency of t3e 3ole )3ermal system.
.
2). !ow to -rotect the condenser from sea water
-lantFcell? What are the
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+inds of such treatment?
)3e marine grot3 is controlled in t3e condenser cooling ater
system 4y inFecting C3lorine.
=aseous C3lorine is dosed intermediately 4y *u4s.
7y*o;C3lorine is inFected continuously.
2,. What are the t"-ical trouble s-ots for air ingress in
a condenser?
a. )ur4ine to Condenser Foints
4. )ur4ine e6*ansion dia*3ragms
c. )ur4ine atmos*3eric valves
d. 5P glands and gland 3ousings
e. 5P 4led;steam lines and feed 3eaters
f. Condenser :ttings ( =auge glass( etc.)
g. Any drain line *assing 4ac/ to t3e steam s*aces of condenser(
erosion at *i*e 4ends can 4e a *articular *ro4lem
2.. What are the methods used to detect the tube lea+
with 0acuum and
with out 0acuum?
Detection met3ods re&uiring vacuum include ?
a. ,oam
4. 7alogen gas
c. #u44ler lea/
d. Indi*lugs
e. Acoustic meters
f. Conductivity measurements
)3ose t3at do not re&uire vacuum includes ?
a. ,luorescein
4. #u44ler lea/
c. ,urmanite guns
d. Corrodogra*3 survey
24. What are the tri- interloc+s for a steam turbine?
a. <acuum very lo
4. 7ot;ell level very 3ig3
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c. <i4ration very 3ig3
d. @63aust steam tem*erature very 3ig3
e. %*eed very 3ig3 (T1.1 times rated s*eed)
f. #oiler )ri*
g. =enerator tri*
3. %team tem*erature very lo
2#7. What are the tri- interloc+s for 3enerator?
a. )ur4ine tri*
4. 5oss of e6citation
c. %tator eart3 fault
d. %tator *3ase to *3ase fault
e. %tator interturn fault
f. >egative *3ase se&uence current 3ig3
g. 9otor tem*erature very 3ig3
3. 5oss of sync3ronism
2#1. What is the limit for -ressure raising with res-ect to
drum metal
Di9erential tem-erature? What is the normal
-ressure raising and
reducing rates in a boiler?
)3e diGerential tem*erature 4eteen to* and 4ottom s3all not 4e
greater t3an "0 Deg.C.
Pressure c3ange rate de*ends on saturation tem*erature of drum
ater. At lo *ressure t3e rate of raise is very small. )3e minimum
time re&uired to raise from 0 to 1 4ar s3all 4e 1 3our assuming t3e
initial drum ater is at atmos*3eric tem*erature.
9ate of increase of saturation tem*erature is +3 Deg.C
9ate of decrease of saturation tem*erature is "$ Deg.C
2#2. What is mean b" start/u- characteristic? What are
the t"-es?
)3e re&uirement of steam *ressure and tem*erature during starting
of a tur4ine de*ends on t3e metal tem*erature. )3e c3aracteristic
s3oing s*eed8load vs steam *ressure88)em*erature is start;u*
c3aracteristic.
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)3e t3ree ty*e of start;u* in any *lant are ?
a. Cold star
4. Barm start
c. 7ot start
2#. What is -erformance diagram of a 3enerator? What
are the limiting
factors?
)3e curve 4eteen 2B (=enerator) vs 2<A9 is t3e 4asic
*erformance cuve.
)3e limitations are ?
a. 2inimum e6citation
4. Practical sta4ility limit
c. 9ated current
d. 9ated 2B out*ut
e. -0 deg. 9otor angle
f. 2a6imum e6citation
g. 2inimum 2B out*ut
3. )ransformer )a* limit
i. =enerator transformer overfu6ing lmit
2##. What is Potier 0oltage and Potier reactance? E<-lain
the relation
between Potier 0oltage and >ero -f cur0e?
9efer to 2odern Poer %tation Practice( <ol.=( %tation 1*eration
and 2aintenance( C3a*ter 3( *ara ".3 (C@=#)
2#'. De?ne &tabilit"? What is the two +ind of stabilit"?
%ta4ility of a generator is de:ned as its a4ility to remain in
sync3ronism it3 t3e *oer system to 3ic3 it is connected.
)3e to regimes of sta4ility are ?
a. %teady state sta4ility
4. )ransient sta4ility
)3e %teady sta4ility of a generator de:nes its a4ility to remain in
sync3ronism under t3e conditions of steady state o*eration. In
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*ractice( t3is also includes load drift( voltage drift and small fairly
slo load c3anges.
)ransient sta4ility de:nes t3e a4ility of t3e generator to return to
its former state of sta4le o*eration after 3aving 4een distur4ed
from t3is state due to sudden c3anges of loading or voltage
conditions. )3e ty*e of c3anges included 3ere are t3ose due to
*oer system faults( load sing( sudden tri**ing of sections of
*oer system netor/( etc.

2#). What is -ower angle e5uation and -ower angle
characteristics of a
generator?
P O <6@8Sd %in D
P ; Poer generated
< ; )erminal voltage
@ ; =enerated @mf
Sd ; =enerator reactance
D ; Delta( Poer angle ()3e direct angle 4eteen rotor load
a6is and >o load a6is
)3e c3aracteristic 4eteen Poer vs D is Poer angle c3aracteristic
of a generator.
2#,. What is function of A8@ in the control of stead"
state stabilit"?
In case of a generator connected to an isolated system it3 no
ot3er sync3ronous *lant *resent( t3en t3e function of t3e AC9 is
solely to maintain a constant 4us4ar voltage( as in t3e static
system.
B3en a**lied to a multi;generator system( t3en voltage regulation
forms one of its functions. Its main eGect is to maintain mac3ine
rotor angle and( t3erefore( to assist in maintaining steady state
sta4ility.
2#.. What is &"nchroni>ing -ower?
B3en a generator suGers a transient distur4ance suc3 as load
surge( t3e rotor oscillates a4out its mean *oer *osition. )3e
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accelerating and retarding action 4eing assisted 4y fo *oer from
or to t3e system. )3is is sync3roniAing *oer.
)3is is transient in action and res*onsi4le for t3e mac3ine loc/ed to
t3e system.

2#4. What are t"-es of electrical motors used in -ower
-lant?
Induction motor and DC motor are mainly used in a *oer *lant.
2'7. What is as"nchronous o-eration of a generator?
Async3ronous o*eration is its o*eration out;of;sync3ronism it3 t3e
rotor une6cited.
2'1. What are the abnormal o-erating conditions of a
generator?
,aults can occur on o*erational *lant. It may 4e re&uired to o*erate
t3e *lant at less fe6i4le o*eration it3 a non correct rated
e&ui*ment. )3is condition of o*eration is a4normal o*eration of t3e
generator.
a. ,ailure of generator transformer
4. ,ailure of e6citer. .sing se*arate DC su**ly
c. 2odi:ed stator it3 reduced conductors
2'2. What are the fault conditions of a generator?
a. %tator eart3 fault
4. %tator *3ase to *3ase fault
c. %tator interturn fault
d. >egative *3ase se&uence current 3ig3
e. 5oss of e6citation
f. Pole;sli**ing
g. 9otor fault
2'. What is cold Pull with res-ect to -i-e su--ort?
%team *i*es ill 4e su**orted 4y s*ring loaded 3angers to
accommodate t3ermal e6*ansion. )3e 3angers ill su**ort t3e
ma6imum load in t3e vertical *osition.
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)3e e6*ansion during normal o*eration ill 4e calculated. )3e
*osition from 3ic3 it ill o4tain vertical *osition ill 4e
determined. )3e su**ort ill 4e :6ed in t3e calculated *osition at
an angle in t3e cold condition. )3e is cold Pull.

2'#. !ow to -reser0e &:) switch/gear? Is it -ossible to
test the brea+er in
the -reser0ed condition and wh"?
)3e %,$ 4rea/ers ill 4e :lled it3 >itrogen to *revent corrosion.
It is not *ossi4le to test t3e 4rea/er in t3at condition.
)3e insulation (dielectric strengt3) of >itrogen is muc3 less t3an
%,$. )3e gas ill 4rea/ don and create eart3 fault.

2''. What is >ero chec+ in the case of -ressure and
di9erential -ressure
transmitters?
In certain *lants( it is *racticed to c3ec/ t3e transmitter Aero
4eteen certain *eriod.
Pressure transmitter and DP transmitters ill 4e isolated from
*rocess. )3e drain ill 4e o*ened for P)s. )3e e&ualiAing valve ill
4e o*ened for DP)s. )3e out*ut s3all 4e ! mA. 1t3erise t3e Aero
ill 4e adFusted to get ! mA..
)3is is similar to one *oint cali4ration for Aero. )3e a4ove is /non
as Aero c3ec/.

2'). What is tem-erature com-ensation of direct drum
le0el gauge? !ow
it is achie0ed and how to o-erate this -ro0ision?
)3e fo t3roug3 t3e normal gauge glass is due to t3e
condensation. )3is ill cause an a**recia4le dro* in tem*erature in
t3e gauge glass. )3e density of ater in t3e gauge glass ill 4e
3ig3er t3an t3at of t3e ater in t3e drum. )y*ically( t3e density of
ater in t3e drum ill 4e 0.$ and t3at of gauge glass is 0.+. %ince it
or/s on monometer *rinci*le( t3e level in t3e gauge glass ill 4e
loer t3an t3at in t3e drum.
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)3is su**ression of level is /non as cold ater su**ression.
)o ma/e t3e levels e&ual( it is necessary to maintain t3e
tem*erature of t3e gauge glass same as drum ater. )3e drain of
t3e gauge glass ill 4e connected to t3e don;comer. )3e
continuous fo t3roug3 t3e gauge glass created 4y t3e drain ill
maintain tem*erature. )3is is called tem*erature com*ensation.
2ore fo of drain ill create a lo level in t3e gauge glass. )o
avoid suc3 condition( t3e fo s3all 4e regulated. A suita4le ori:ce
ill 4e *rovided in t3is line. )3e siAe ill 4e :6ed during
commissioning of t3e 4oiler.
2',. What is the -rocedure for -re/commissioning a soot
blower after
com-letion of erection?
%oot 4loer s3all 3ave a minimum slo*e of " deg. )oards t3e
furnace( to clear t3e condensate after o*eration. )3e furnace ill
3ave e6*ansion of furnace 3en it is on load. )3e ot3er end ill 4e
su**orted from structure it3 slot for sliding.
)3e cold condition s3all 3ave slo*e to *rovide t3e a4ove slo*
during 3ot condition.

2'.. What are the 2urbo &u-er0isor" Instruments?
)3e tur4o su*ervisory Instruments are *rovided to monitor
essential moving *arts during start;u* and s3ut;don. )3e
*arameters are ?
a. )ur4ine %*eed
4. DiGerential @6*ansion
c. @ccentricity
d. #earing vi4ration
e. <alve *ositions
2'4. !ow the &-eed control will wor+ after s"nchroni>ing
in a turbine
control?

%*eed control ill act as Droo* control after sync3roniAing.
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2)7. What is the allowable 0oltage 0ariation for a
3enerator?
Plus "E and minus 'E
2)1. What is !J2 alignment ?
%ome times t3e s3aft ill 4e s3ifted u*ards 4y t3ermal e6*ansion
of t3e driven e&ui*ment( 3en running. )3e s3aft s3all 4e
3oriAontal during running. )o ac3ieve t3is( t3e s3aft of t3e motor
and driven e&ui*ment ill 4e miss;aligned in t3e cold condition.
)3is is 3ot alignment.
2)2. What is the sim-le control?
,eed;4ac/ control is t3e sim*le control. It can 4e used it3out
/noing t3e *rocess.
2). What are the basic com-onents of a control?
@rror calculator( control out*ut calculation algorit3ms and
Auto82anual transfer sitc3 are t3e 4asic com*onents of a control.
@rror is de:ned as t3e diGerence 4eteen t3e %et *oint and t3e
*rocess value.
Deviation is t3e diGerence 4eteen t3e *rocess value and set *oint.
2)#. What are the basic control algorithms?
Pro*ortional gain or #and( Integral and Derivative are t3e 4asic
algorit3ms of a feed;4ac/ control.
Pro*ortional gain?
)3e gain 4y 3ic3 t3e out*ut ill 4e modi:ed 3en t3ere is an
error.
)3e a4ove out*ut ill 4e *ro*ortional to t3e error.
Pro*ortional #and?
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)3e E error 4y 3ic3 t3e out*ut ill c3ange 4y 100E is
*ro*ortional 4and.
Integral is many time is /non as 9eset time.
)3e time in 3ic3 t3e out*ut ill 4e modi:ed 4y t3e value e&ual to
error( 3en t3e error remain same during t3e *eriod.
Derivative out*ut is *ro*ortional to t3e rate of c3ange of t3e error.
)3e time is t3e 4y 3ic3 t3e out*ut ill go to $3.3E of t3e initial
value.
In modern control( t3e out*ut ill 4e *ro*ortional to t3e rate of
c3ange of P< instead of error.
2)'. When to use Deri0ati0e in a control?
Derivative is a**lied to com*ensate t3e dead;time due to
measurement. It s3all 4e used in control 3en t3e measuring
instrument ill cause a dead;time in t3e measurement.
Derivative s3all not 4e used 3en t3e *rocess value is it3 noise.
)3is ill cause continuous fuctuation in t3e *rocess.
2)). What are the t"-es of -rocess?
Processes are divided to ty*es as *er control.
%elf;regulating ty*e?
)3e *rocess 3ic3 ill o4tain a ne steady value 4y itself c3ange
in t3e control valve is self;regulating ty*e.
@6.[ Pressure( )em*erature( ,lo( etc.
%elf;integrating or non self regulating ty*e.
)3e *rocess 3ose value ill go on c3ange until t3e saturation
after t3e c3ange
in control valve is self;integrating ty*e.
@6.? 5evel( etc.
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2),. What are the control enhancements?
,eed Iforard( Case;cade( over;ride( %*lit range( etc. are some of
t3e en3ancement a**lied to control to im*rove
*erformance8sta4ility.
2).. What are the methods used for tuning a controls?
.ltimate 2et3od
Can 4e a**lied for ty*e of *rocesses.
Process res*onse 2et3od.
Cannot 4e a**lied for %elf;Integrating ty*e.
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