2016 Test Paper-1 Solutions

Indian BOE Coaching Service
2016 BOE Exam Test Paper-1 Solutions

Paper-1 (Boiler Engineering-1)
Date : 08.05.2016 Time : 01.30hrs. Max. Marks :100
Note : Attempt any 5 question whether question No. 1 is compulsory. Each question has equal marks.
Q.1 : (a) In a boiler test the following quantities were obtained. [10]
Mean temperature of feed water 59*C
Mean boiler pressure 12bar
Mean steam dryness fraction 0.95
Mass of coal burnt per hour 250kg
Calorific value of coal 32400Kj/Kg
Mass of water supplied to the boiler in 7hour and 14minutes 16500kg
Mass at the end of the test was less than that at the commencement by 1000kg
Calculate the thermal efficiency of the boiler and actual equivalent evaporation from and at 100*C per
kg of coal.
Solutions :
Ms =Mass of steam generation per hour
=Net mass of water supplied per hour
=(16500-1000)/7.25=2138 kg/hr
From steam table at 12 bar hf=798.4kj/kg & hfg=1984.3kj/kg
Hs =Specific enthalpy of steam at 12 bar
= hf+x.hfg=798.4+0.95x1984.3=2683.485kj/kg=641.68kcal/kg
Thermal efficiency of boiler = Heat output/Heat Input
=Msx(Hs-hf)/QxGCV
=[2138x(641.68-59)]/[250x(32400/4.182)]
=1245769.84/1936872.31=0.6432=64.32%
Mact =Mass of steam generation/Mass of fuel consumption=2138/250=8.552

Factor of equivalent evaporation “F” =(Hs-hf)/539=(641.68-59)/539=1.081
Actual equivalent evaporation from and at 100*C per kg of coal =
=MactxF =8.552x1.081=9.245
b) The percentage composition of a sample of coal on mass basis is as follows Carbon 85%,Hydrogen
12%, Oxygen 3%
(i) Determine the minimum air required for complete combustion of 1kg of coal.
(ii) If Air supplied is 1.5times the minimum air required, calculate the mass of dry product of
combustion per kg of coal burned.
(iii) The heat carried away by the dry product of combustion leaving the boiler per kg of fuel burned.
Given average specific heat of dry flue gas is 1.005 Kj/kg*K and temperature of flue gas is 375*C and
boiler house temperature is 25*C. [10]
Solution :
Given that, Carbon=85%,Hydrogen=12%,Oxygen=3%
Theoretical air requirement for complete combustion of 1 Kg of coal
=100/23x(2.67C+8H+S-O)
=100/23x(2.67x0.85+8x0.12+0-0.03)
=4.35x3.1995
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=13.89 kg of air per kg of coal burnt (Answer)
While Excess air is 50% ,hence actual air requirements
=1.5x13.89 =20.84 kg of air per kg of coal burnt
Total excess air quantity
=20.84-13.89 =6.95 kg/kg of coal
Total product is of combustion here includes CO2,H2O,Excess O2,N2.
To find the products of combustion is,
(i) Weight of CO2 formed per kg of coal= 3.67xC=3.67X0.85=3.1195Kg
(ii) Weight of H2O formed per kg of coal=9XH=9x0.12=1.08Kg
(iii) Weight of Excess O2 per kg of coal=0.23x6.96=1.5985Kg
(iv) Weight of N2 per kg of coal= 0.77x20.84=16.0468Kg
Out of 4 combustion product H2O is not considered in dry product of combustion.
Hence Dry flue gas of combustion consist of CO2,Excess O2,N2.
Therefore total weight of dry flue gases
w= 3.1195+1.5985+16.0468
=20.76 kg/kg of coal burnt (Answer)
Heat loss through dry flue gas =wxCpxΔT
=20.76x1.005x(375-25)
=7302.33 KJ/kg of coal
Heat carried away by dry flue gases of combustion
=heat carried away per kg of moisture in flue gas x weight of H2O formed per kg of coal
=2940x1.08
(2940 Kj/kg heat liberated through flue gas due to hydrogen present in fuel)
=3175.2 KJ/Kg
Total heat loss per kg of coal for heat carried away by flue gases
=7302.33+3175.2 =10,477.53 KJ/Kg (Answer)
Or
b) A boiler is equipped with a chimney 25 meter high. The temperature of outside air is 25*C and
average temperature of flue gasses in the chimney is 320*C. If the boiler is supplied 20kg of air per kg
of fuel burnt. Calculate (a) The theoretical draft created in cm of water and
(b) The velocity of flue gases in the chimney if 60% of the draught is lost in friction at the grate and
passage. [10]
Solution :
Given as, Ta (Ambient temp is 25*C=25+273=298*K
H=25meters ,T=320*C=320+273=593*K ,w=20kg/kg of coal burnt
Theoretical draught h=353H(1/Ta-w+1/wx1/T) mmWc
h=353x25(1/298-21/20x1/593)
h=8825x(0.00336-1.05x0.00169)
h=8825x0.00156
h=13.767 mmwc=1.3767cmwc
Available draught is 40% of the theoretical draught.

P=0.4X13.767=5.5068 mmwc=5.5068X9.81N/m2
Now this pressure is caused by height of gas column Hg
Hgx353(w+1)/wxTx9.81=5.5068X9.81
Or Hgx353(20+1)/(20x593)x9.81=5.5068x9.81
Or Hgx1.6=5.5068
Draught head of hot gasses is Hg=3.44m
Velocity of flue gas in chimney= V=√(2xgxHg) =√(2x9.81x3.44) =8.22 m/sec
Q.2 : Write short notes on any 4 of the followings. [4x5=20]
a. Advantages & disadvantages of surface condenser over jet condenser.
b. Advantages of supercritical boiler over subcritical boiler.
c. Priming, foaming & carryover.
d. Boiling mechanism.
e. Post weld treatment
f. Advantages and disadvantages of welded joint over Riveted joint.
Answer :
a. Advantages & disadvantages of surface condenser over jet condenser :
ADVANTAGES OF A SURFACE CONDENSER
The various advantages of a surface condenser are as follows:
1. The condensate can be used as boiler feed water.
2. Cooling water of even poor quality can be used because the cooling water does not come in direct contact
with steam.
3. High vacuum (about 73.5 cm of Hg) can be obtained in the surface condenser. This increases the thermal
efficiency of the plant.
DISADVANTAGES OF A SURFACE CONDENSER
The various disadvantages of' the surface condenser are as follows:
1. The capital cost is more.
2. The maintenance cost and running cost of this condenser is high.
3. It is bulky and requires more space.
b. Advantages of supercritical boiler over subcritical boiler :

c. Priming, foaming & carryover :
Priming : Priming is the sudden discharge of water with steam from the boiler. It is just like the bumping of
water that repeatedly accompanies rapid heating on a open vessel.
Priming is caused due to following reasons:
1. Improper designing of boiler.
2. Improper method of firing.
3. Overloading of boiler.
4. Sudden change in load.
5. Combination of two or more above factors at same instant.
Priming can be reduced by following ways :
(i) By installation of steam purifiers.
(ii) Lowering water level in boiler drum.
(iii) Maintain constant load (Avoid pulsating steam demand).
Foaming : Foaming is the formation of small and stable bubbles into the boiler water.
Foaming is caused due to following reasons :
1. Higher percentage of dissolved solid.
2. Excessive alkalinity.
3. Presence of oil in boiler water.
Higher concentration of solids form small size of steam bubbles. This type of bubbles are much more stable in
nature , do not burst easily. The foaming contaminates the steam with desired amount of boiler water which
contains the corrosive salts.
Carryover : Boiler water solids are also carried over in the moisture mixed with steam even when there is no
indication of either priming or foaming. This type of process known as carryover. Carryover may be partly
mechanical or partly chemical problem. Whereas mechanical causes as follows :
(i) Boiler design.
(ii) Higher water level in boiler drum.
(iii) Overloading in boiler.
(iv) Fluctuation in load on boilers.
(v) Possibility of carryover will be more if steam storage space are too small in boiler drum.
Normally steam from boiler carries 0.5 to 1.5% moisture in the form of mist or fog. In modern high pressure
boiler carryover of moisture limited about 0.1%.
d. Boiling mechanism : Remember that an express a machine facilitate to basic function to make express
and to steam. The different boiling mechanism determine how efficiently it can do these two action express
brewing temperature should be around more temperature. Generally in boiler mechanism there are three type
of boiling mechanism:
1. Nucleate boiling: It is formation and release of steam bubbles at the tube surfaces with water still wetting
the surface immediately. since the tube temperature at surface is closer to saturation temperature the tube is
always safe against failure.
2. Film boiling: Film boiling is the formation of steam film at the tube surface in which the metal temperature
rise sharply. this lead to instantaneous or long term over heating of tubes and failures. film boiling begins due
to high heat flow or low velocity or inclined tubes.
3. Transition boiling: Transition boiling is a stage in between nucleate and film boiling having features of both
of these stages.
e. Post weld treatment : The post weld treatment is carried out by heating the component in the furnace, or
through local heat treatment by heating circumferential band encompassing the heat affected zone and the
weld zone. Heating a bandwidth five times the radius multiplied by the thickness and lagging a bandwidth of
double its size on both the sides ensures sufficiently low temperature gradient. It is carried out below the lower
critical temperature to avoid excessive oxidation of the surface.
f. Advantages and disadvantages of welded joint over Riveted joint :

Advantages :--
1. Efficiency is more.
2. Lighter structures can be made.
3. Has greater strength.
4. Addition and alteration can be easily made.
5. Tension members are not weakened.
6. Rigid frames can be made.
7. Process of welding takes less time.
8. Drilling or punching of holes does not required.
9. Required smaller section for same load.
10. Smooth in appearance as well as painting is easier and economical.
Disadvantages :--
1. Need high level of skilled labour and supervision.
2. Due to uneven heating and cooling the members may get distorted or additional stress may develop.
3. Inspection is little bit difficult.
4. No provision of expansion or contraction in the frame, therefore cracks may develop.
Q.3 : Define the following definitions as per IBR Act-2007. [5x4=20]

a. Boiler. b. Economizer. c. Steam Pipes.
d. Super-heater. e. Boiler components.
Answer :
a. Boiler : “Boiler” means a pressure vessel in which steam is generated for use external to itself by
application of heat which is wholly or partly under pressure when steam is shut off but does not include a
pressure vessel,-
(i) with capacity less than 25 liters (such capacity being measured from the feed check vale to the
main steam stop valve);
(ii) With less than one kilogram per centimeter square design gauge pressure and working gauge
pressure or
(iii) In which water is heated below one hundred degrees centigrade
b. Economizer : “Economizer” means any part of a feed-pipe that is wholly or partially exposed to the action
of flue gases for the purpose of recovery of waste heat.
c. Steam Pipes : “Steam-pipe” means any pipe through which steam passes, if-
(i) the pressure at which steam passes through such pipe exceeds 3.5 kilogram per square centimeters above
atmospheric pressure, or
(ii) such pipe exceeds 254 millimetres in internal diameter and the pressure of steam exceeds 1 kilogram per
square centimeters above the atmospheric pressure, and includes in either case any connected fitting of a
steam-pipe)
d. Super-heater : “Super-heater” means any equipment which is partly or wholly exposed to flue gases for
the purpose of raising the temperature of steam beyond the saturation temperature at that pressure and
includes a re-heater.
e. Boiler components : “Boiler component” means steam piping, feed piping, economizer, super-heater,
any mounting or other fitting and any other external or internal part of a boiler which is subject to pressure
exceeding one kilogram per centimeter square gauge;

Q.4: a) Explain function of Boiler mounting and boiler accessories. Name 6 Nos. of each? [12]
Answer :
Q.4: b) A circular beam of 105mm diameter is subjected to shear force of 500kg. Calculate the value of
maximum shear stress and sketch the variation of shear stress along the depth of the beam. [8]
Solution :
Diameter of beam=105mm =0.105m

Area A=π/4xd2=3.14/4x0.105x0.105=0.00865m2
Shear force S=500kg=500N=0.5kN
Mean shear stress
ζmean=S/A=0.5/0.00865=57.8kN/m2
Using the relation,
Maximum shear stress ζmax =4/3xζmean
=4/3x57.8=77.07kN/m2

Q.5 : (a) What is meant by good, perfect & complete combustion. What is the role of excess air. [8]
Answer : Three T’s of combustion : Homogeneous mixture of carbon and oxygen content is important. To
ensure good combustion is controlling the "three T's" of combustion which are
(1) Temperature high enough to ignite and maintain ignition of the fuel,
(2) Turbulence or intimate mixing of the fuel and oxygen, and
(3) Time, sufficient for complete combustion.
Too much, or too little fuel with the available combustion air may potentially result in unburned fuel and carbon
monoxide generation. A very specific amount of O2 is needed for perfect combustion and some additional
(excess) air is required for ensuring complete combustion. However, too much excess air will result in heat and
efficiency losses. Usually all of the hydrogen in the fuel is burned and most boiler fuels, allowable with today's
air pollution standards, contain little or no sulfur. So the main challenge in combustion efficiency is directed
toward unburned carbon (in the ash or incompletely burned gas), which forms CO instead of CO2.
Perfect, good and incomplete combustion : Here mention three comparative figures are showing the
difference combustion process with changing of air & fuel ratio .
Role of Excess Air : For optimum combustion, the real amount of combustion air must be greater than that
required theoretically. Optimization is most important in the view of complete combustion. It can be monitored
by residual oxygen content in flue gas. Theoretically no oxygen content should be in flue gas because it is
leading to more heat loss from furnace. But practically it not possible to maintain zero excess oxygen content
because there must be few content of oxygen to ensure complete combustion. If we try to maintain higher
oxygen content in flue gas then possibility of complete combustion is more the other part is that heat loss will
be proportionally higher. Hence to ensure minimum heat loss along with complete combustion slight part of
oxygen content should be indicated in Orsat apparatus for oxygen monitoring. Excess air is nothing but a
higher content of air more than that the calculated theoretical air. Higher excess air means it is leading to heat
loss but lowering of excess air is leading to poor combustion. Hence optimization is most important factor in
combustion point of view.
Q.5: b) Discuss briefly about principle on which ESP works & List out different parts name of ESP. [12]
Answer :
Principle of ESP(Electrostatic Precipitator) operation:
# High DC –ve potential is applied to discharge electrode with respect to grounded collecting plate.
# Above di-electric strength, the break-down of medium takes place.
# Discharge of free electrons from emitting electrode which move towards collecting plates.

# Ionize gas molecule & charges dust particle negatively.
# These negatively charged dust particles moves towards collecting plate, gets collected & loose their charge.
Q.6 : a) A hollow shaft is to transmit 300 kw at 80 rpm. If the shear stress is not to exceed 60 N/mm2
and internal diameter is 0.6 of the external diameter. Find the external and internal diameter assuming
the max torque is 1.4 times the mean torque? [10]

Q.6: b)What method are there for preservation of boiler during shutdown? Explain any one of them.[10]
Answer : Boiler preservation: Boiler preservation is process when putting the boiler idle/stopped condition for
non-operational condition for short/long period. There are two methods of boiler preservation for during boiler
shutdown :
1. Wet preservation : The wet system is used when Boiler is to be placed on stand by for short period of
time or when the unit may be required on short notice.
2. Dry preservation : The dry system is used when a unit is out of service for extended periods.
1. Wet preservation: If the boilers are required to be kept out of service, but are likely to be required as
standby units, the wet method is a practical one, by which a unit could be made ready for service. In the
wet method, the boiler is filled through the economiser with deaerated treated water to give the required
alkalinity, and the boiler is fired with low sulphur fuel, and steamed in service so that the boiler water will be
circulated to secure uniform concentration throughout the unit, and the oxygen eliminated from the water.
The boiler load should then be reduced slowly and the water level raised as high in the gauge glass as its
consistent with safe operation, while delivery some steam a concentration of 100 ppm of hydrazine should
be maintained for preventing oxygen corrosion. When air cocks reveal no pressure in the boiler, and
before a vacuum can be produced, the boiler should be filled in by deaerated water, until water spills over
and fills the super-heater using a high point air vent, such as pressure gauge connection as an indicator.
The drum air cock should be connected to a surge tank located above the steam drum to ensure positive
pressure and prevent ingress of air to the boiler, thus compensating for volumetric changes due to
temperature.
After firing the boiler, the setting should be closed and maintained in a closed condition. Periodical
inspections may be carried out to observe if condensation has occurred on external surfaces, and if this
happens, heating devices may be placed at convenient points to keep metal surfaces above dew point. In
wet storage, the boiler must be protected from frost. If the ambient temperature is likely to be dropped to
freezing point, this type of storage must be avoided.
A protective coating should be applied to auxiliary equipment. All moving parts should be rotated once in a
week and also electrical equipment attended to. Oil lubricated bearings should also be attended to as
suggested by the manufacturers for the equipment not in use. Generally gearboxes and such applications
are drained and cleaned, and filled with medium viscosity oil excluding air.
Boiler connections should be checked for leakages and water samples analyzed. If hydrazine
concentration has dropped below 50 ppm, chemicals should be injected to bring the concentration to
normal after lowering the level. The boiler should then be steamed sufficiently to circulate the water added
with chemical and the procedure followed as stated above. In any case, if the boiler is to be stored for
unduly long periods, it should be emptied and inspected for corrosion defects.
2. Dry preservation: For dry storage the boiler must be cleaned properly and dried thoroughly, since the
moisture may cause corrosion of metal surfaces. Precaution must be taken to prevent entry of moisture in
any form, from steam, feed and air lines. For this intent moisture assimilating material such as quick lime at
the rate of 0.9 kg (2 lb) or silica gel at the rate of 4.5 kg (10 lb) for 4546 litres (1,000 gallons) capacity,
should be placed on trays inside the boiler shells or drums to absorb moisture from the air. The manholes
should then be closed and all connections on boilers tightly banked. The serviceability of the materials for
such purposes and their replacement may be judged through regular internal boiler inspections.
Alternatively, dried air may be circulated through the boiler.

Q.7 : a) Single element and three elements drum level control. [10]
Answer :
Q.7: b) Describe about any one of the following external water treatment process (i) Softener,(ii) DM
Plant, (iii) R O Plant. [10]



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2016 BOE Exam Test Paper-1 Solutions

Mact =Mass of steam generation/Mass of fuel consumption=2138/250=8.552

Available draught is 40% of the theoretical draught.

b. Advantages of supercritical boiler over subcritical boiler :

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

f. Advantages and disadvantages of welded joint over Riveted joint :

Q.3 : Define the following definitions as per IBR Act-2007. [5x4=20]

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

Diameter of beam=105mm =0.105m

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

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

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

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

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

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

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