QUESTION BANK BASED ON PREVIOUS YEAR QUESTION PAPERS

Power Plant Design/ Engineering

HEAT EXCHANGERS
June 2017

July 2016
July 2015

July 2014

July 2011
43800 Ib/hr of 42° API Kerosene leaves the bottom of distilling column at 390°F and will be
cooled to 2000 F by 149000 Ib/hr of 340 API mid continent crude coming from storage at 1000 F
and heated to 1700 F. A 10 psi pressure drop is permitted on both streams. A combined dirt
factor of 0.003 should be provided. Available for this service 211/4 inch ID exchanger having
158 number of tubes, 1 inch OD, 13 BWG, 16 ft long and layed out on 11/4 inch square pitch.
The bundle is arranged for 4 passes and baffle plates are spaced 5 inch apart. Will the exchanger
suitable? What is the dirt factor? 25

It is desired to heat 9820 Ib/hr of cold Benzene from 800 F to 1200 F using toluene which is
cooled from 1800 F to 1000 F. The specific gravities at 680 Fare 0.88 and 0.87 respectively. A
fouling factor of 0.001 should be provided for each stream and allowable pressure drop of each
stream is 10 psi. A number of 20 ft hair pins of 2 inch by 1.25 inch IP are available. How many
hair pins are required? 25

Extra
It is desired to heat 4454,35 ks/hr (9820 lb/hr) o f gold benzene from 26.67°C’ (80° F) to
48.88°C’ (120° F) using toluene which is cooled from 71.11°C’ (160°F) to 37.78°C’ ( 100°F).
The specific gravities at 200C1 (680f) are 0.88 and 0.87 respectively. A fouling factor o f 0.001
should be provided for each stream and allowable pressure chop of each stream is 0.702 bar
(lOPsi). a number of 5.095m(20ft) hair pins of 50.8mm ( 2 inch) by 31.75mm ( 1,25inch) Ip are
available. How many hairpins are required? 25
Air Preheater, Economiser
June 2017

July 2016

July 2015

July 2014

July 2011
A quantity of 500000 Ib/hr of fuel gas from a boiler is cooled from 7000 F while 400000 Ib/hr of
air at 800 F is heated upto 4000 F. Design a suitable tubular air heater. 2 inch OD x 0.087 inch
thick carbon steel tubes are available. Assume ST/ d = 1.5 and SJd = 1.27 having inline
arrangement. 16

Extra
a) Flue gas from a boiler leaves at 415.5°C (780°F). Mass o f gas flowing is 340200 kg/hr
(750,000 lb/hr). It is proposed to install an economizer to heat 226800 kg/hr (5X105
lb/hr) of feed water from 82.2° C’ (180 OF) to 104.4°C ( 220° f) using waste gas.
Estimate the heat transfer area and exit gas temperature. Assume !J= 20Btu/ f^ -h r^ F ^
104.6 w7m20C' 8

b) In a tubular API I in which air sets heated by Hue gas has the following data:
8
Quantity o f air flow= 9.52X 104 kj/hr (21x104 lb/hr)
Quantity of flue gas= 1.08X 105 kj/hr (2.4x105 lb/hr)
Temperature o f flue gas at inlet= 537.7°C (1000°F)
Temperature of air at inlct= 37.7°C (100°F)
Overall heat transfer coefficient^ 5 Btu/ft2/hr-°F (26.15w/m2C).
Heat transfer area = 464.5M2 ( 5000 ft2)
CP for gas = 0.25, CP for air =0.24 check exit gas and air temperature.

Superheater n reheater design

June 2017

July 2016

July 2015
July 2014

July 2011

Extra:
What are important factors to be considered for super heater and reheater design? 5
Steam Condenser
June 2017

July 2016

July 2015

July 2014
July 2011
A quantity of 220,000 Ib/hr of steam 1.5 inch Hg has to be condensed using cooling water at 600
F. 9/lO cupronickel tubes of 3/4 inch 00 of thickness 14 and 20 BWG are available. It is desired
to limit exit cooling water temperature to 750 F from cooling tower performance considerations.
A value of 950 BTUjlb may be used for latent heat. Assume the initial velocity = 5 fps and
number of passes = 2. 50

Cooling tower
June 2017

July 2016

July 2015

July 2014

July 2011
a. Explain the influence of the following process conditions on the design of a cooling tower:
 Unsaturation of the inlet air
 Close approach
 Stagging
 Changing Operating Pressure. 20
Extra
A quantity of 27.72 kg/sec ( 220000 lb/hr) o f steam at 0.03386 bar ( 1.5 inch Hg) has to be
condensed using cooling water at 15.550C' (600F) cupronickel tubes of 25.4mm ( 1 inch) OD
and 19.05mm ( 0.75 inch) OD o f thickness 14?18 and 20 BWG are available. It is desirable to
limit exit cooling water temperature to 23.89°C ( 75°F) from cooling tower performance.
Calculate value o f 278.35 ( 950 Btu/lb) may be used as latent heat. Study the alternative and
suggest the optimum choice. 50

A cooling tower 7.315X7.315 m ( 24by 24ft) w'as designed to deliver 1654 ton/h(1500gpm) of
water from 48.8r°C to 29.45fl,C( 120° to 85°F). When the 5% WBt was 23.88°C ( 75°F). Fans
arc capable of delivering 5292nr7min the tower be capable of performing to full fill the process
requirements? Determine i) by numerical integration ii) by using log mean enthalpy difference,.
30
Hxplina the influence of the following process conditions on the design o f a cooling tower.
20
i) IJn-saturation o f the inlet air. iii) Slugging
ii) Close approach iv) changing operating pressure.
Boiler Furnace design
June 2017

July 2016

July 2015
July 2014

July 2011

In a boiler having circulation ratio of 4 at a pressure 1595 psi absolute, mass velocity through the
water wall tubes is 62068 Ib/fe hr, boiling occurs over a lenth of 137.79 ft. The tube size is 2.5
inch 00 and 0.2 inch thick. Estimate the total pressure drop. 15
Extra
Determine the appropriate furnace exit gas temperature o f a boiler when net input is about
586.132X106 W ( 2000X106 Btu/hr) o f which 4512.883X106W( 1750X106Btu/hr) is due to
fuel and rest is due to air, HHV and LHV of coal are respectively 23260 Kj/kg( 10,000 Btu/lb)
and 20934 Kj/kg(9000 Btu/lb) and a furnace heat release ratt o f 252416 W/m2( 80,000 Btu/ft2
hr) (projected area basis) has been used. The values of Ew and Ef maty be taken as 0.6 and 0.5
respectively. 25% excess air is used. Water all outer temperature is 315.55°C (600°f). Ash
content is coal is 10%. 10

b) In a boiler having circulation ratio od 4 (qualify 25%) at a pressure P= 104 bar (150PSi). mass
velocity through water wall tube is 1229020 kg/m2/hr(600 000 lb/ft2 hr), boiling occurs over a
length of 34.8m (100ft). tube size is 63.5 mm (2.5inch (OS and 5mm (0.197 inch) thick. Estimate
the total pressure chop. 9