Gujarat Boiler Examination Board Boiler Operation Engineer Exam-2017

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Gujarat BOE-2017 Paper-2 (Boiler Engg-2) Solution

GUJARAT BOILER EXAMINATION BOARD
BOILER OPERATION ENGINEER EXAM-2017
PAPER-2
Section-I
Q.1: Note [Objective questions papers were collected back by examiner after the
examination.] Total numbers of objective question were asked- 30 Nos. (01 Marks
each) Total of 30 Marks.
Section-II
Date : 07/10/2017 Time : 02.30PM to 05.30PM
Day : Saturday Marks : 70
Instructions :
1) Attempt all Questions.
2) Draw sketch where ever required.
3) Marks for each question indicated on right side.
4) All answers of one question should be at one place.
Q.2 : Answer the following questions(Any Four) [20 Marks]

Q2.1 : Write stepwise procedure for for starting erection of new boiler. What kind
of load to be considered for boiler civil foundations and what precautions to be
taken during civil foundations of boilers, fan and BFP.
Answer : New Boiler Erection Sequence:

It becomes all the more important for the job site erection group to take utmost care right
from the receipt stage to completion of erection, so that commissioning activities can
proceed without any difficulties. The major components in pressure parts to be erected
are :
1. Boiler Foundation & Civil jobs.
2. Boiler Structures Erection.
3. Boiler drum Erection
4. Headers Erection
5. Water – walls and stream cooled walls Erection.
6. Economizer Erection.
7. Air preheater Erection
8. ESP Erection.
9. Stack(Chimney) Erection.
10. Super – heater and re-heater coils Erection
11. Buck – stays Erection.
12. Hydraulic test to be done.
13. Welding & NDE.
14. Flue gas duct Erection.
15. Auxiliaries & Fans Erection
16. Fuel feeding System Erection
17. Ash disposal system Erection.
18. Chemical dosing system Erection.
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Load to be considered for boiler civil foundations :
1. Dead load
2. Live /Imposed loads
3. Static and Dynamic loads for piping rotating equipment etc.
4. Cable trays and walkways supported on columns.
5. Ash water piping support
6. ESP hopper ash filled up condition to the extent of top of the hopper .
7. To calculate the load the ash density to be taken 1350 kg/ m3 8. Ash load at the
bottom of hopper and pent house as specified in the mechanical contract.
9. Wind load and seismic load .
10. Temperature load ( +/- 25 c ) for atmospheric temperature variations.
11. Temperature load for variation of temperature due to ESP operating conditions.
12. Boiler structure should be so designed that temperature of the structure should not
go beyond 60 deg.
13. Bracing for pipe supports on ESP should be less than 10.0 Mtr height.
14. Plinth level of Boiler area will be 500mm higher than FGL ( Finished Grade Level).
15. Finished floor level of boiler area paving shall be kept about 200 mm lower than the
finished floor level of Main Plant buildings.
Boiler/Fans/BFP etc. foundation system general requirements are :-
A. Foundations can be open ( isolated footing /raft) or pile foundation depending on soil
report.
B. The design of foundations should be as per different IS codes.
C. No Major foundations should be on filled up soil.
D. Open foundations and pile foundations should not be combined in same structure.
E. Foundations should be designed on worst combination of loads.
F. For open foundations minimum width is 1.0 M and depth is 1.0M below NGL.
G. Permissible settlement of open foundation of 6.0 M and below span is 40mm
Permissible settlement of open foundation of 6.0 M and span(raft) is 75mm Permissible
settlement on weathering rock is 12mm.
H. For pile foundations the diameter of pile shall be 600mm diameter minimum . Vertical
compression load will be 140MT. The uplift and lateral load capacity will be 20% and 5%
respectively.
I. Initial Pile Load test to be carried out for each diameter.
Vertical (Compression) -3
Lateral (Horizontal) -3
Uplift (Tension) -3
Q2.2 : Explain method for monitoring and control of boiler water level, furnace
draft, combustion control and air control by automation.
Answer : 1. Boiler water level control by :
(i)Single-element control : This uses a single control loop that provides regulation of
feed water flow in response to hanges in the drum water level from its set point. The
measured drum level is compared to its set point, and any error produces a signal that
moves the feed water control valve in proper response. Single-element control will
maintain a constant drum level for slow changes in load, steam pressure, or feed water
pressure. However, because the control signal satisfies the requirements of drum level
only, wider drum-level variation results.
duration”
(ii)Three-element control : This uses a predetermined ratio of feed water flow input to
steam flow output to provide regulation of feed water flow in direct response to boiler
load. The three-element control regulates the ratio of feed water flow input to steam flow
output by establishing the set point for the drum-level controller. Any change in the ratio
is used to modify the drum-level set point in the level controller, which regulates feed
water flow in direct response to boiler load. This is the most widely used feed water-
control system.
2. Draught Control : The function of draft in a combustion system is to exhaust the

products of combustion, i.e.flue gases, into the atmosphere. The draft can be classified
into two types namely:
1.Natural draft
2.Mechanical draft
(I) Natural draft : Natural draft is the draft produced by a chimney alone. It is caused by
the difference in weight between the column of hot gas inside the chimney and column of
outside air of the same height and cross section.Being much lighter than outside air,
chimney flue gas tends to rise, and the heavier outside air flows in through the ash pit to
take its place. Draft is usually controlled by hand-operated dampers in the chimney and
breeching connecting the boiler to the chimney. Here no fans or blowers are used. The
products of combustion are discharged at such a height that it will not be a nuisance to
the surrounding community.
(II)Mechanical draft : It is draft artificially produced by fans. Three basic types of drafts
that are applied are:
(i) Balanced draft: Forced-draft (F-D) fan (blower) pushes air into the furnace and an
induced draft (I-D) fan draws gases into the chimney thereby providing draft to remove
the gases from the boiler. Here the pressure is maintained between 0.05 to 0.10 in. of
water gauge below atmospheric pressure in the case of boilers and slightly positive for
reheating and heat treatment furnaces.
(ii) Induced draft: An induced-draft fan draws enough draft for flow into the furnace,
causing the products of combustion to discharge to atmosphere. Here the furnace is kept
at a slight negative pressure below the atmospheric pressure so that combustion air
flows through the system.
(iii) Forced draft: The Forced draft system uses a fan to deliver the air to the furnace,
forcing combustion products to flow through the unit and up the stack.
3. Combustion Controls :Combustion controls assist the burner in regulation of fuel

supply, air supply, (fuel to air ratio), and removal of gases of combustion to achieve
optimum boiler efficiency. The amount of fuel supplied to the burner must be in
proportion to the steam pressure and the quantity of steam required. The combustion
controls are also necessary as safety device to ensure that the boiler operates safely.
Various types of combustion controls in use are:
1. On/Off control: The simplest control, ON/OFF control means that either the burner is
firing at full rate or it is OFF. This type of control is limited to small boilers.
2. High/low/off control: Slightly more complex is HIGH/LOW/OFF system where the

burner has two firing rates. The burner operates at slower firing rate and then switches to
duration”
full firing as needed. Burners can also revert to the low firing position at reduced load.
This control is fitted to medium sized boilers.
3. Modulating control: The modulating control operates on the principle of matching the
steam pressure demand by altering the firing rate over the entire operating range of the
boiler. Modulating motors use conventional mechanical linkage or electric valves to
regulate the primary air, secondary air, and fuel supplied to the burner. Full modulation
means that boiler keeps firing, and fuel and air are carefully matched over the whole
firing range to maximize thermal efficiency.
4-Air flow control methods : There are 3 methods of fan control as follows :
(i) Damper Control : The simplest form of damper consists of a hinged plate that is
pivoted at the centre so that it can be opened or closed across the duct. This provides a
form of draught control but it is not very linear and it is most effective only near the
closed position. Once such a damper is more than about 40- 60% open it can provide
very little additional control. Another form of damper comprises a set of linked blades
across the duct (like a Venetian blind). Such multi bladed dampers are naturally more
expensive and more complex to maintain than single-bladed versions, but they offer
better linearity of control over a wider range of operation.
(ii) Vane Control : The second form of control is by the adjustment of vanes at the fan
inlet. Such vanes are operated via a complex linkage which rotates all the vanes through
the same angle in response to the command signal from the DCS.
(iii)Variable-speed drives : Control of fan throughput can be achieved by the use of
variable speed motors (or drives). These may involve the use of electronic controllers
which alter the speed of the driving motor in response to demand signals from the DCS
or they can be hydraulic couplings or variable-speed gearboxes, either of which allows a
fixed-speed motor to drive the fan at the desired speed. Variable speed drives offer
significant advantages in that they allow the fan to operate at the optimum speed for the
required throughput of air or gas, whereas dampers or vanes control the flow by
restricting it, which means that the fan is attempting to deliver more flow than is required.
Q2.3 : Describe primary,secondary and tertiary air used in boiler combustion.
Answer :
Primary air : The purpose of primary air control is to regulate the quantity of air that
reaches the fire bed or grate in order to control the burn of fuel.
Secondary air : The purpose of secondary air control to regulate the qty of air that is
received above the fire bed or grate to ensure that combustion process is complete and
efficient.
Tertiary air : The purpose of tertiary air is that a third stage of admission of air to a
combustion system, the reactions of which have largely been completed by secondary
air.
Q2.4 : List out various materials specification in boiler components and piping for
medium and high pressure and temperature boiler.

duration”
Answer :
Material Used for various pressure parts of

Super-critical Boilers :
Q2.5 : What is Smurt? What is the causes of its emission? How Smurt emission
could be prevented?
Answer : Unable to Answer.

duration”
Q.3 : Answer the following Questions(Any Four) [Marks 20]
Q3.1 : What is volatile matter in coal and how it is determined ? How much % of
volatile matter available in coal and its effect in combustion.
Answer : Volatile matter is defined as the % loss in weight when a finely ground coal
specimen is heated in a closed vessel at 1200*k for 40 minutes.After cooling and drying
in a desicator the residue ( coal) is weighed.
% volatile matter = 100% - ( coal + moisture )
Thus the volatile matter is an index of gaseous fuels present.Range of volatile matter is
20 to 35% .
Volatile matter –
 Proportionately increases flame length,and helps in easier ignition of coal.
 Sets minimum limit on furnace height and volume.
 Influences secondary air requirement and distribution aspects.
 Influences secondary oil support.
Q3.2 : What are the cause of silica slippage from a mixed bed ?
Answer : 1. Resin may be exhausted.

2. Improper anion exchanger regeneration because of inadequate separation during
backwash.
3. Fouling of anion excahange resin by organic substances.
4. Not maintaining the correct quality and concentration of regenerant.
Q3.3 : What steps to be taken in case of heavy noise noticed from furnace?
Answer :
Following actions to be taken if any heavy noise noticed from furnace :
1. Fuel feeding has to be stopped immediately and checked adequate reason.
2. Check the steam flow and feed water difference of last few hours.
3. Try to maintain desired water level in drum.
4. Inform higher authorities immediately without any time delay.
5. If required, Boiler MSSV has to be closed & maintain boiler pressure through start-up
vent.
Q3.4 : What steps to be taken in case of abnormal condition of boiler back fire?
Answer :
1. Check for boiler tube leak.
2. Check the ID Fan for failure.
3. Check the flue gas path.
4. Check the APH tube for leakage.
5. Boiler has to be stopped immediately, if back fire is uncontrolled.
Q3.5 : What is the positive circulation ?What do you mean by circulation ratio and
list out advantage of positive circulation?

duration”
Answer : Positive circulation : If the working fluid is forced through the boiler circuits
by an external pump,the ensuing circulation is called Positive or Forced circulation.
Circulation ratio = Circulation ratio is the ratio between mass of flow rate of circulating
water in boiler to generate unit mass of steam generation.
CR=Mass of flow rate of circulating water/Rate of steam generation
(k) =Gfw/Gs
Circulation ratio for the natural circulation type boiler is in the range of 4 to 30.
Circulation ratio for the forced circulation type boiler is in the range of 3 to 10.
Circulation ration for Once through boiler is 1(unity).
Advantage of positive circulation :

1- Steam generation is high
2- Greater capacity to meet load variation
3- Quicker start up quality from cold
4- Lower scaling problem due to high circulation velocity
5- Smaller tube diameter and hence lighter tubes
6- More uniform heating of all parts reduces the danger of overheating and thermal
stresses.
Q.4 : Answer the following Questions. (Any Four) [Marks : 20]

Q4.1 : Discuss the effect of flue gas re-circulation.
Answer : Water vapour in the FG absorbs more heat than air alone.FGR dilutes the
excess air in the combustion zone .
The flue gas recirculation quenches the peak flame temperature in the combustion zone
and reduces superstoichiometric oxygen level. As a consequence NOx formation is
reduced.
Q4.2 : Super heater.
Answer : Superheater : The steam coming out from drum through saturated steam
pipes is dry and saturated. The saturated steam flow takes its passage through set of
coils, called Superheater, where further heat is added to increase steam temperature at
constant pressure. Superheater is generally located above furnace, at high radiant and
convection heat zone. Superheating is also done in stages through a set of
Superheaters e.g., Primary Superheater and Secondary Superheater.
Classification of Superheater :
1. Radiant Superheater: The Superheater, which is located virtually above of the
furnace, is designated as Radiant type. It is so called because mainly the heating
surface of this type of Superheater receives heat by radiation process from the hot
combustion zone.
2. Convection Superheater: The convection Superheater receives heat mainly by
transfer through convection process. The exposed heating surface of the Superheater is
in continuous contact with flue gas passing through.
3. Horizontal or vertical Superheater: The Superheater can be arranged either
horizontally or allowed to be hung vertically. The vertical arrangement is simpler in
supporting and allowing for expansion and this arrangement is called pendant type.
duration”
Horizontal superheater needs supporting of the tubes at multiple points to avoid sagging
and expansion movement should also be permitted. However the horizontal construction
provides the advantage of draining.
4. Parallel or Counter Flow Superheater: The surfaces can be designed or placed in
such a way hat the flow direction of flue gas and steam is parallel or opposite. Counter
flow arrangement has the advantage of minimum surface but the metal temperature at
the leaving section is high compared to parallel flow.
Q4.3 : PRDS.
Answer : PRDS - Most modern boilers generate steam at high pressures &
temperatures. High pressure steam has lesser volume than steam at atmospheric
pressure, thereby translating into smaller boiler size & lower diameter of steam piping.
Also, high temperature (superheated) steam has more energy, which translates into
higher efficiency for power generating steam turbines.
On the other hand, all process industries use low pressure low temperature saturated
steam, primarily due to the following reasons:
 Saturated steam has the highest heat transfer efficiency.

 Lower pressures & temperatures translate into thinner pipes, lighter flanges &
less expensive materials thereby significantly reducing initial plant cost.
In any industry, steam is required at different locations, but the required steam pressure
& temperature at each location varies according to the application. Therefore, high
pressure superheated steam is generated at a central location (boiler), distributed to
various locations in the plant through a steam piping network, and then reduced to the
operating pressure & temperature just upstream of the usage points.
Some applications of PRDS stations are enumerated below:
 1. PRDS for process heating / cooling applications in sugar, food, textile, paper
etc. plants
 2. Deaerator, Ejector PRDS for boiler
 3. Turbine bypass PRDS
Q4.4 : What is steam trap? List out various types of steam trap and explain
inverted bucket steam trap with neat sketch.
Answer :Steam trap – The function of steam trap is
1 – To discharge the condensate as soon as it is formed

2 – Not to allow steam to escape
3 – To be capable of discharging air and other incondensable gases.
Types of steam traps –
A –Thermostatic trap
B – Mechanical trap
C – Thermodynamic trap
duration”
Inverted bucket steam trap :
Above Figure shows an inverted bucket trap condensate enters through the lower
connection and through the upturned pipe that project into the inside of the inverted
bucket. Any air, trapped inside the bucket escape through the small leak hole. The
condensate accumulates inside the trap body and inside the bucket. Provided the
condensate is entering fairly fast the leak hole will be inadequate to even out the
pressure inside and outside the bucket. That way the water level will rise faster outside
the bucket than the inside. This gives the float buoyancy and keeps the valve shut. As
the condensate sufficient water has been blown out of the bucket, its buoyancy is
restored; it rises and closes the valve, leaving the trap in the position shown in the figure.
Now it is clear that the bucket would retain its buoyancy unless the steam and/or air
inside the bucket could escape. Air escapes through leak hole and is eventually
discharged with the condensate. Steam escapes through the leak and is condensed in
the body or the trap. During discharge steam blows straight thorough the leak hole out of
the discharge, but the quantity so lost is so small that it is of little importance. The valve
opening force is the weight of the bucket as in the open bucket type. The valve closing
force is the buoyancy of the bucket.
Q 4.5 : What are the advantages of thermal spray coating?
Answer : The advantages of thermal spray coating are:
 Reduced Cost. The cost of repairing the component is less than buying a new
one. Often, the coating actually lasts longer than the original material used.
 Low Heat Input. With few exceptions, the thermal spray process leaves the
component’s thermal history alone.
 Versatility. Almost any metal, ceramic or plastic can be thermal sprayed.
 Thickness Range. Depending on the material and spray system, coatings can be
sprayed from 0.001 to more than 1 inch thick. The thickness typically ranges from
0.005-0.1 inch.

duration”
 Processing Speed. The spray rates range from 3-60 lb/hr depending on the
material and the spray system. Typical rates for material application are 1/2 -2 lb
of material per sq ft per 0.01 inch thickness.
Q.5 : Answer the following Question. (Any Two). [Marks : 10]
Q 5.1 : Airprehater and reheater .
Answer : Air-preheater: Combustion is a process of vigorous chemical reaction of a

fuel with Oxygen and ther equired Oxygen is received from atmospheric air, which is
available in abundance innature. We have seen earlier for proper combustion of a fuel
three ‘T’s i.e. Time,Temperature and Turbulence are essential. Time and Turbulence can
be created bysupply of combustion air at a required pressure, velocity and direction. To
sustain thetemperature of burning fuel, it is also essential to supply combustion air
preheated tohigher Temperature. Perfect and efficient combustion of fuel can be
achieved in a boiler,if the atmospheric air can be preheated by the low temperature flue
gas, which isotherwise going to be wasted through the chimney. Hence a device called
‘Air Preheater’is used in boilers for the purpose of preheating combustion air by the flue
gas and then issupplied for fuel combustion.
Re-heater : - Superheated steam at specified pressure and temperature from boiler is

supplied to steam engines/steam turbines. While expanding and doing work over several
stages of turbine wheels, the pressure and temperature drops at every stage and finally
reaches a bare minimum pressure. The final pressure depends on whether it is to be
released for process utilization or the exhaust steam can be condensed in condenser
and the condensate is recycled. In some of the large steam turbines, steam after doing
work through a few stages, substantially looses its pressure and temperature and the
enthalpy thus gets reduced. Cycle efficiency can be improved, if the steam is extracted
out from the highpressure cylinder and again taken to boiler, where by addition of heat,
the steam temperature is increased. The apparatus where such heat addition is
accomplished is called Reheater and comprises a set of coils of tubes, located in boiler
furnace where the steam is reheated. Reheaters are located ahead of final Superheater
in the direction of flue gases and in the convection zone.
Q 5.2 : What is the difference between deaeration and deoxygenation?
Answer : Deaeration is the removal of both O2 and CO2 from water while
deoxygenetation involves the removal of O2 only. Deaeration is the thermal
method.Watre is heated to bring about degasification,whereas deoxygenation is carried
out mainly by chemical techniques.
Q 5.3 :What is vanadium corrosion? Where it can attack and how it can be reduce?
Answer : It refers to attack of superheater tubes by the vapour of vanadium pentoxide

formed in the furnace gases. If the fuel contains sodium, the furnace gases will contain,
among other, sodium vanadate (Na2O.5V2O5.V2O4 ) a low fusing compound ( 6000c )
forming a thin film of corrosive liquid on the superheater tube surface at 6100c –
6200c .This film attacks carbon, low alloyed and austenitic steels.
duration”

Gujarat Boiler Examination Board Boiler Operation Engineer Exam-2017

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Indian BOE Coaching Services

Gujarat BOE-2017 Paper-2 (Boiler Engg-2) Solution

Q.2 : Answer the following questions(Any Four) [20 Marks]

Answer : New Boiler Erection Sequence:

Answer : 1. Boiler water level control by :

2. Draught Control : The function of draft in a combustion system is to exhaust the

3. Combustion Controls :Combustion controls assist the burner in regulation of fuel

2. High/low/off control: Slightly more complex is HIGH/LOW/OFF system where the

Q2.3 : Describe primary,secondary and tertiary air used in boiler combustion.

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

Material Used for various pressure parts of

Answer : Unable to Answer.

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

Answer : 1. Resin may be exhausted.

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

Advantage of positive circulation :

Q.4 : Answer the following Questions. (Any Four) [Marks : 20]

Q4.2 : Super heater.

 Saturated steam has the highest heat transfer efficiency.

Some applications of PRDS stations are enumerated below:

Answer :Steam trap – The function of steam trap is

1 – To discharge the condensate as soon as it is formed

Q 4.5 : What are the advantages of thermal spray coating?

Answer : The advantages of thermal spray coating are:

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

Q.5 : Answer the following Question. (Any Two). [Marks : 10]

Q 5.1 : Airprehater and reheater .

Answer : Air-preheater: Combustion is a process of vigorous chemical reaction of a

Re-heater : - Superheated steam at specified pressure and temperature from boiler is

Q 5.2 : What is the difference between deaeration and deoxygenation?

Answer : It refers to attack of superheater tubes by the vapour of vanadium pentoxide

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