Following are mostly asked questions in Interview with Thermal Power

Plant:

1. What is primary separator and secondary separator in boiler drum?

2. What is induction motor principle?

3. Simple boiler internal diagram?

4. What is mean by HP and LP dozing?

5. Draw condenser to boiler drum scheme path?

6. Draw switch yard to line single line diagram?

7. What is mean by attemperation location and where are its sources for super heater
and re heater?

8. What is the percentage of nitrogen and oxygen in air?

9. What is mean by LDC and SLDC and what they do?

10.What are the sources for PRDS? (AST header source)

11. What is the AST output?

12.What are the cooling tower types?

13.What is mean by dry ash and wet ash? (dry ash – bottom ash in ESP)

14. Explain the dry ash to silo path?

15. Explain heat triangle?

16. What is the value of drum pH level?

17. What is mean by CBD and EBD?

18. What is salient pole and non-salient pole?

19. Why hydrogen is used in generator instead of air?

20. Explain GT protection

21. LA, WT, CT, CVT, PT – draw symbols?

22. Explain RH protection?

23. What are the protection of boilers?

24. What is mean by proximity analysis and ultimate analysis?

25. Why deareator and what is its function?

26. Condensate extraction pump works at what pressure?

27. why speed is maintained at 3000 RPM?

28. what are the different types of governor?

29. different types of compressors in power plant?

30. different types of Air used in power plant?

31. from mill house fuel is transported to boiler?

32. classification of turbine?

33. different types of soot blowers used in thermal power plant?

34. whether stator conductor is hollow?

35. why CDP drain is open?

36. what is mean by RO? (reverse osmosis)

37. explain mill protection?

38. what are the types of valves?

39. safety valve and EPRV valve?

40. explain air conditioning cycle?

41. draw DM plant scheme?

42. SWS parameters?

43. what is mean by scanner air fan and explain?

44. explain EOP?

45. explain JOP, AOP, Injector?

46. where is MOP located?

47. what is mean by drag link chain conveyor?

48.what is fastener’s types.

49.explain ESP principle?

50.explain ACW uses?

51. what is mean by Drip and Drain - draw the scheme?

52.what is normal drain, emergency drain and alternate drain?

53.seal trough uses?

54.what is the percentage of ash in coal.

55.working principle of chimney?

56.what is mean by acid dew temperature?

57.explain natural draft cooling?

58.explain LP/HP bypass?

59.what is mean by purging/

60.what is the cost of LDO and HFO ?

61. relation of pressure , volume in fluid mechanics?

62.what is the nozzle principle?

63.method of ash disposal in silo.

64.what is the heat remove in the condenser/

65.commissioning of boiler?

66.what is the sequence of oil burner?

67.atomization- why we need to do that?

68.what is on-load tube cleaning?

69.what is the purpose of condenser?

70.what is long retractable soot blower and why it is used?

71. what is mean by hydro test?

72.What is mean by MFT?

73.what are the turbine protections?

74.what are the boiler protections?

75.what is DG? (diesel generator)

76.what is GIS? (Gas insulated substation)

77.What are the types of breaker?

78.what is the principle of ejectors?

79.explain bottom ash handling?

80.how many safety valves are present?

81. what is buccholz relay?

82.what is governing?

83.what are the types of Air used in power plant?

84.what are the types of extinguisher and where it is used?

85.explain ESP principle?

86.what is induction motor principle?

87.what are the various level of voltage in power plant?

88.what is the steam source for GSH.

89.deluge valve in the conveyor

90.method of extinguishing fire inside the mill? (mill inert steam)

91. what is drift in cooling tower?

92.what happens if stator conductors gets punctured?

93.what is mean by GDS? (gas distribution screen)

94.explain centrifugal and centripetal forces?

95.what is scoop in hydro coupling?

96.centrifuge ? how does it work? And where does the water enters inside it?

97.what is ETP.

98.draw PT and CUT symbols.

99.LHS in coal handling system?(hint – conveyor safety)

100.what is corona? And where it is used?

101.ESP collecting and emitting electrodes terminals?

102.types of voltages in power plant?

103.PRDS system?

104.difference between metal detector and magnetic separator difference?

105.how fly ash gets collected in the ESP?

106.explain transformer cooling

107.protection of power plant?( class A, class B)

108.what are the furnace losses?

109.how many relays are there in MFT?

110.when MFT will get activated?

111.explain nozzle principle?

112.what is acid cleaning?

113.what is CEP?

114.what is the purpose of deareator?

115.explain Fahrenheit?

116.what is the purpose of ID fan?

117.what are the DC power voltage level?

118.what are the DC equipments in power plant?

119.what is the purpose of cooling tower?

120.what is steam blow out?

121.what is soot & how it is formed and methods to reduce soot?

122.what is soot blowers. What is the operating conditions of soot blowers?

123.direction of rotation of tri-sector RAPH with respect to flue gas duct?

124.how many boiler safety valves. What are the operating condition of boiler safety
valves.

125.what is JOP, MOP?

126.what is LP dozing and HP dozing?

127.where is ammonium dozed in boiler?

128.what is drip and drain?

129.what is static and dynamic excitation?

130.what is CRO?

131.PLCC why it is used?

132.HRH,CRH which tubes are bigger in size?

133.what is seal air fan?

134.Types of fire extinguishers?

135.whare are the solid, liquid and gaseous pollutants.

136.how is bottom ash is disposed?

137.why chimney is at that particular height?

138.different between RO and DM plant?

139.what is EOP?

140.explain hydrogen evacuation? Explain the percentage ratio?

141.what is soot blowing?

142.what is the moisture content in coal?

143.what are the types of mills?

144.what is dew point?

145.how is PF coal is taken to the furnace and at what temperature?

146.protections in generator?

147.when MFT initiates?

148.chemical dozing in boiler drum? Why?

149.what is deluge valve? How it works?

150.how to detect condenser tube leakage?

151.explain modified rankine cycle?

152.explain difference between fly ash and bottom ash?

153.purpose of scanner air fan?

154.usage if FD fan?

155.draw the flue gas path?

156.what are the various voltage levels?

157.what is attemperation.

158.BFP stages?

159.how fly ash is disposed?

160.types of draught?

161.types of fans?

162.drift losses?

163. ID fan usage?

164.generator output voltage level.

165.what is the kg of coal require to generate one unit?

166.calorific valve of coal.

167.difference between wet bulb and dry bulb temperature?

168.explain air ventilation?

169.LPT diaphragm?

170.what is 3T.?

171.what is scaling?

172.what is SAT, UAT, ST?

173.what is the unit of sound?

174.explain cooling tower principle?

175.what lighting arrestor? And where it is used?

176.what is ETP?

177.what is isotopes?

178.what is centrifuge?

179.what is service air?

180.baring gear in LMW?

181.what is the pressure of seal oil?

182.difference between instrument air and service air?

183.how moisture is removed in instrument air?

184.what is centrifuge and why it is called centrifuge?

185.CPU – condensate polishing unit?

186.excitation system?

187.HP/LP bypass – scheme?

188.why deaerator is in high level and why booster pump is used?

189.needle valve, where it is used?

190.difference between globe valve and gate valve?

191.how butterfly valves work?

192.where CBD and EBD valves are located?

193.what is priming in pumps?

194.deaerator pegging steam?

195.why NRV is used after pump, why can’t be used before pump?

196.what is air preheater?

197.how bore well pump sucks water from below 100 feet?

198.whether main ejector is in service with the circuit?

199.AST used in what all places?

200.boiler – purpose, components and combustion

201.soot blower types?

202.excitation static type, dynamic type block diagram

203.what is grid?

204.fuel calorific valve? Ash and moisture content? Indian coal and imported coal?

205.capacity of power in tamil nadu?

206.what is SCR?

207.gland steam condenser – principle of steam collecting

208.transformer rating?

209.what is diaphragm?

210.what is AVR and how it is controlled?

211.SCR thyristor didoe symbol purpose?

212.what is firing angle?

213.what is mill inert steam/

214.PLF and availability factor?

215.DM plant scheme?

216.where conduction, convection and radiation takes place in boiler?

217.boiler safety valve location?

218.sequence of safety valve operation?

219.centrifuge working?

220.cycles of concentration in cooling tower?

221.thermodynamic first law?

222. Rankine cycle and modified rankine cycle difference?

223.Difference between entropy and enthalpy?

224.turbo separator process?

225. GT protection?

226. Location in boiler where flue gas temperature is high?

227.sequence of oil gun operation?

228.what is global warming?

229.what is acid rain?

230.what is green house effect?

231.what are the emergency equipment to be running during black out?

232.bunker to boiler scheme?

233.carbon content and volatile content?

234.what is HGI?

235.atomization in LDO and HFO?

236.bowl bill and beater wheel mill?

237.air compressor?

238.emulsifier?

239.FCNRV?

240.steam cycle and condensate cycle?

241.different types of water in plant?

242.sealing system?

243.red colour is more prevalent than other colours? Why?

244.corona in ESP?

245.what is drip , drain and alternate drain?

246.abrasive, corrosion and erosion?

247.seal oil system vacuum pump location?

248.why recirculation is taken for CEP after GSC.

249.motoring of generator?

250.temperature of primary air?

251.stress relieving?

252.state henry law?

253.chlorination in power plant?

254.coagulation, flocculation and sedimentation?

255.isometric?

256.what is eddy current?

257.lamination in core of transformer?

258.seal labyrinth?

259.what is shrouds?

260.FD fan and ID fan – axial and radial fan?

261.burner tilting?

262. What is PA fan and purpose and what happens if PA fan trips?

263.what is vector group?

264.absolute pressure and gauge pressure?

265.what is CT and PT?

266.what is steam blow out and alkali boil out?

267.material used in SH, RH water wall?

268.what is EDTA?

269.what is passivation?

270.electrical energy calculation?

271.what are the permissive to start a mill?

272.what are the purging permissive?

273.what are the boiler losses?

274.why unburnt carbon deposit in the bottom?

275.what is BMS?

276.scheme condenser to deaerator?

277.what is black out and emergency run?

278.effect of cooling water puncture?

279.methods for ash disposal?

280.explain rankine cycle?

281.what is seal trough?

282.boiler expansion?

283.economizer recirculation

284.CEP will create vacuum or not?

285.what is hydrogen gas cooler?

286.what is CEP drain?

287.why 3 safety valve in HRH & drum?

288.why re heater is necessary?

289.carbon content in different types of coal?

290.boiler efficiency?

291.generator synchronizing parameters to be matched?

292.explain turbine trips?

293.what is heat rate?

294.what are the boiler protection.

295.what is GIS? Its purpose?

296.what is SF6 circuit breaker?

297.scheme of FD fan to chimney?

298.unit of capacitance, inductance and frequency?

299.explain CT, CVT, PT?

300.difference between static and dynamic head?

301.turbo super visionary?

302.what is pumped storage plant?

303.difference between hydro power plant and TPS?

304.hydrogen is stored in or not stored after removing it from generator?

305.losses in TPS?

306.why ID fan capacity is more?

307.flue gas outlet at RAPH , why oxygen is more, what is the reason?

308.cooling of circulating water?

309.have u seen MOCB near cooling tower?

310.why we use SF6 as medium why can’t we use nitrogen?

311.what is the advantage of CFBC.

312.steam blow out disturbance factor?

313.COC ? how much to be maintained?

314.WBT ,DBT difference between those in cooling tower?

315.uses of cooling medium in transformer?

316.how water is used to cool the generator and why water is not getting short circuited
inside generator?

317.why water is not used in transformer for cooling purpose?

318.what happens when scanner fan air trips?

319.what are the primary and secondary fuel in boiler?

320.What is PA and seal air?

321.what is transformer breather?

322.what is wave trap?

323.water critical pressure?

324.why ESP collecting electrode is +ve?

325.what is subzero cooling?

326.mill reject?

327.3 element control?

328.what heat is rejected in the condense? Why sensible heat is not rejected in
condenser?
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               BOILER QUESTIONS AND ANSWERS
Q. What are boiler losses?

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POWER PLANT INTERVIEW QUESTIONS &

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 A. Generally the boiler efficiency is considered as 85%,here are

the boiler losses considered as,
1. Heat loss in dry flue gas loss-10.7%.
2. Heat loss due to moisture in fuel - 2.2 %.
3. Heat loss due moisture in air - 0.38 %.
4. Heat  loss due to formations of water from H2 in fuel - 4.4%
5. Heat loss due to conversion of C to CO- 0.53%
 Q. what is critical point of steam?
 Ans. It is the point at which all water vapor  converts to
steam .The critical point occurs at a temperature of 374 deg &
224.6 kg/cm2 .The point is called critical point and the pressure,
temperature at this corresponding saturation  temperature is
known as critical pressure and critical temperature.Here the   
density of steam and water will remain same.
Q. What is evaporation ratio of Boiler?
 Ans. It the ratio of quantity of steam generation in kg/hr  to
quantity of fuel consumed in kg/hr. 
Evaporation ratio = quantity of steam generation/quantity of
fuel consumed.For example quantity of steam Is  310 ton/hr and
fuel is 55 ton/hr then the evaporation  ratio is 5.63. Evaporation
ratio is also known as steam fuel ratio.A drop in evaporation
ratio indicates drop in boiler efficiency.Boiler evaporation ratio
depends on fuel quality. Higher calorific value of fuel having
higher evaporation ratio.
Value of evaporation ratio for different types of boiler is listed
as-
a) Coal fired boiler- 4.0-6.0.
b) Oil fired boiler- 13.0-14.5 .
c) Gas fired boiler- 11.0-13.
 Q. what is acid due point in boiler ?
 Ans.The temperature at which the formation of sulfuric
acid in the boiler is   known as acid due point,It is generally
in between 130-140 deg celsius. As fuel contain sulfur
dioxide (SO2) & H2O at certain temperature both are
condense together and sulfuric acid(H2SO2)  is formed.
It will corrode the boiler tubes.To avoid acid due point we
can use,
1>FD fan re circulation system.
2> By using steam coil air pre-heater (SCAPH).
3> FD air bypass system.
  Q. What is slagging or fouling in boiler ?
 A.Slagging is the formation of molten or partially fused
deposits on the furnace surface or radiation zone . Fouling
is the deposition of fused particle on convection zone such
as super heater & re- heater.
 Q. What is proximate analysis of coal ?
 Ans.it is the analysis of coal in which we can find
moisture,volatile matter,fixed carbon & ash.we can found
above parameter as,
 moisture-Take 1gm of coal sample heat in a woven at 105
deg for 01 hr.
 Moisture + volatile matter- Take 1gm of coal sample heat
in a woven at 950 deg for 07 minute.
 Ash- Take 1gm of coal sample heat in a woven at 720 deg
until the coal is completely burnt.
 Q. What is the ultimate analysis of coal ?
 A. This is the most accurate method of coal analysis.In
this analysis we can found the components of the mass of
carbon,hydrogen,oxygen,nitrogen,sulfur,moisture,ash.
so (c+h+o+n+s+m+a)= 100% mass.

Q. What is gross calorific value and net calorific value

of coal?
Ans.
1.calorific value:- It is the amount of heat liberated with a
unit mass of coal for  1g Kcal.
2.Gross calorific value:-It is the amount of heat liberated
by the complete  combustion of unit weight of fuel with
subsequent cooling of   product(moisture/water vapor) .
G.C.V is more than N.C.V.
3. Net calorific value :- It is the heat produced in complete
combustion when the product of combustion are allowed
to escaped.

           N.C.V = G.C.V - Latent heat of water vapor.

           N.C.V = (G.C.V-0.09x587)cal/gm.

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               TURBINE QUESTIONS AND ANSWERS

Q. What is steam turbine?

Ans.The turbine is a rotary machine which converts heat
energy of steam into mechanical energy. The steam
contain both pressure and temperature known as
enthalpy .
Working- When steam allowed in the turbine the kinetic
energy of steam at the expense of (enthalpy) is convert to
mechanical energy. As the steam moves over the blades
due to change of direction and centrifugal force of
isometric expansion causes to rotate the blade.
Type of steam turbine:- There are generally two types of
steam turbine.
1. Impulse turbine- Here the steam is expanding in the
fixed nozzle and the pressure drops at each stage. The
high velocity of steam entering in the nozzle does work in
the moving blades which causes shaft to rotate. The main
features of this turbine are maximum pressure drops in
the nozzle.
2. Reaction turbine- In this type of turbine the pressure is
dropped in both fixed and moving blades. The both fixed
and moving blades act like a nozzle. Work done is
obtained due to impulse effect (Reversal of direction of
high velocity steam) plus reaction effect of (Expansion of
steam) trough the moving blades. The velocity of steam is
proportional to the square root of heat drop in the nozzle.
Q.What are Classifications of steam turbine:-

Ans. The steam turbine are classified as under,

1. According to number of cylinder-
a) Single cylinder.
b) Double cylinder.
c) Three cylinder.
2. According to steam flow :-
a) Axial flow turbine-Here the steam flows parallel to the
axis of turbine.
b) Radial flow turbine- Here the steam flows perpendicular
to the axis of the turbine.
3. According to the method of governing:-
a) Throttle governing-Steam enters trough the throttle
valves.
b)Nozzle governing- steam enters through two or more
nozzles.
c) Bypass governing- Here the steam is divided two or
more stages of turbine.
4. According to the principle of action:-
a) Impulse turbine.
b) Reaction turbine.
5. According to the heat balance arrangement:-
a) Condensing turbine-Here the steam is condensed
through a condenser .
b) Back pressure turbine- The exhaust steam is used in the
purpose of industrial or process heating purpose.
6. According to pressure used:-
a) Low pressure turbine.
b) Medium pressure turbine.
c) High pressure turbine.
7. According to shaft arrangement.
a) Tandem compound -Here the shaft are arranged in
single shaft.
b) Cross compound – Here the shaft are arranged to drive
different generators.
8. According to casing:-
a) Single shell casing.
b) Double shell casing.

Q. What Is turbine heat rate?

 Ans. It the ratio of heat input to MW generated in
kcal/kWh.
   = steam flow(enthalpy of steam-enthalpy of feed water) /
MW.
Q. What are the turbine losses?
A. The turbine losses are mention here as,
a)Tip Leakage loss- This loss is happen due to the
clearance in between the fixed and moving blades.
b) Friction loss- This loss is due to the fluid friction in
nozzle and rotor blades.
c) Leaving loss- This loss is considered due to the leaving
of steam in last stage of blade without doing further useful
work.

Q. why maximum steam turbine double shell casing is

provided?
Ans.The double shell is preferred because,
 . a) For quick start up of turbine.
   b) Less stress developed in the casing due to double
casing.

Q. What are the types of condenser used in steam

turbine?
Ans. There are two type of condenser is general used in
steam turbine as,
 a) Jet condenser: - In this type of condenser exhaust
steam and cooling water is directly mixing together. Here
very high quality of cooling water is needed. The quantity
of cooling water required is very less as compared to
surface condenser.
b) Surface condenser:- Here the cooling water is flowing
through tube shells and the exhaust steam is cooled
through the contact of cooling water tubes.
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                 TURBINE QUESTIONS AND ANSWERS

Q. What is vacuum?
Ans. The vacuum can be defined as a state of very low
pressure or we can say that a space of no matter. It is
below the atmospheric pressure and measured in
(mmHg).
Q. What is the effect of high vacuum in Turbine?
Ans. We can't maintain very high vacuum in steam turbine
because,
a) Turbine last stage is designed with 12% wet steam ,very
high vacuum will lead to  increase wetness in last stage so
it will reduce the mechanical strength of turbine last blade
as the volume of steam increase.
b) Due to high wetness corrosion of last blade will
increase.
c) The condensate water will goes to under cooling due to
low saturation pressure so more coal and sensible heat
required to rise the temperature of condensate.
d) Due to high vacuum condenser tube may be
compressed.

Q. What is the effect of low vacuum in a steam

turbine?
Ans. By maintaining vacuum in a turbine the work done of
turbine will be increase because vacuum will reduce the
back pressure of the turbine hence there is more pressure
difference in between the turbine and more work
done.Vacuum helps to convert of steam to water by
providing low saturation temperature.

Q. What is gauge pressure and absolute pressure?

Ans. Absolute pressure :-  It is the pressure which is zero-
referenced against
vacuum.                                                                                         
The absolute pressure = gauge pressure + atmospheric
pressure.
Gauge pressure :-  It is the pressure which is zero
reference to atmospheric
pressure.                                                                                     
Gauge pressure = absolute pressure – atmospheric
pressure.
Q. What is Electro - Hydraulic governing control of
turbine?
Ans. Now a days most of the turbine speed is controlled
through this type of governing. It is the governing system
in which the turbine speed is controlled by electrical
sensing and hydraulic control. This type of governing
provides very faster speed response than the other
governing. The turbine speed is measured through a
electrical speed transducer mounted on the HP end of the
turbine rotor.
Q. What is eccentricity of steam turbine?
Ans. It is defined as the deviation between the center axis
of the shaft to outer diameter of the turbine rotor .This
happen due to uneven cooling of turbine after shutdown
condition. Due to this effect the shaft may be got
permanent damage and the fixed blade may touch to
moving blades. The eccentricity is measured when the
turbine speed is <240 rpm .
Q. What is the NAS value of oil ?
Ans. The NAS stands for National  Aerospace Standard, is
used to find the contamination of oil. The NAS value is
maintained 6 for turbine oil servo-46.The water
concentration of oil should not exceed more than 300
ppm.
Methods of oil sampling:- The oil sample is always taken
from a upward pipe with continuous flow. The sample
taken between the pump and filter.
Q. What is diaphragm of a steam turbine?
Ans. The diaphragm is used in steam turbine to prevent
leakage steam passing through fixed and moving blades. It
is the partition in between the fixed blade and moving
blade of steam turbine. Generally labyrinth seals are used
for diaphragm. One half of diaphragm is fitted into the top
casing and another half is fitted into the bottom casing. It
works as a seal in between fixed and moving blade. It
increase the turbine efficiency.

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               BOILER QUESTIONS AND ANSWERS

Q. What are the heat transfer mediums

Ans.  There are generally three medium as,
a) Conduction:- Here the heat is transferred through
molecules. The molecules move from one part to another
part of the substance. Liquid are the good conductor
where as vapor and gaseous are poor conductor of
conduction medium.
b) Convection: - Here the heat is transferred through
movement of heated medium. The heated medium moves
from one place to another place due to density difference.
This medium is used in boiler furnace.
b) Radiation: - Here the heat is transferred through
gasses or vacuum. The heat transfer depends on the
fourth power of body’s absolute temperature.
Q. What is boiling?
Ans. There are two boiling process used in medium
heating.
a) Nucleate boiling: - Here the heat added in such a
manner that the heat received from the inner wall of the
container and the droplets are individually converted into
steam bubbles. As the bubbles grow the size they move to
upward due to lighter density. Other bubbles take their
space and the process continues till the container heated.
b) Film boiling: - This is called film boiling, because a
bubble film is created at the inner surface of the
container. If the heat flux added  is greatly increase to a
certain value the bubbles are  adjacent  to each other
instead of detached and  a film is formed at the inner wall
of the container. This bubble film act as a poor conductor
of heat. The bubbles get super heated and finally increase
the temperature of container and may lead to failure of
container / tube. The deviation of boiling process from
nucleate boiling to film boiling is known as departure from
nucleate boiling (DNB).
Q. What are the circulations are used in boiler?   
Ans. There are three types of circulation is generally used
in boiler as,
a)Natural circulation:- This circulation happen due to
density difference of  the two medium. In boiler the two
medium are water and steam, as steam is lighter than the
water it pushes to upwards flow of water steam mixture,
the steam is separated in drum and water comeback
through down comer to again water wall. This circulation
use thermo- siphon principle. This circulation limited to
operating pressure below 175 kg/cm².
b) Assist circulation:- In this circulation the medium
moves through a mechanical pump. The pump overcome
the frictional loses in the tube. This type of circulation
used pressure beyond 175 kg/cm² .The pump is placed in
between the down comer and bottom ring header of
water wall.
c) Forced circulation / once through system:-  This
system  used in boiler above  critical pressure. Here the
feed water is directly fed from the beginning of the circuit
to end of the circuit without circulation. No drum used in
this system. Super critical boilers are designed for once
through system.
Q. What is stoichiometric combustion?
 Ans. It is defined as the theoretical combustion in which
fuel is burnt completely. It is used to determine the actual
theoretical air required for a proper combustion.
Q. What are the types of boiler?
Ans. There are two types of boiler is generally used,
a) Water tube boiler:- Here water is flowing  through the
tube. The hot gasses pass through tube and heat transfer
takes place. Now a day’s most of boiler are water tube
boiler.
b) Fire tube boiler:- Here hot gas passes through the tube
and tube is immersed with water. Heat transfer takes
place from the hot flue gasses and steam is collected from
top of cell. This boiler used in for small steam demand.
The solid combustible hot gas settle inside the tube which
reduce heat transfer.
Q. What are the types of economizer is used in boiler?
A. There are two type of economizer used in boiler as,
a) Steaming economizer:- Here some of the water is
converted to steam and the steam-water mixture flows
through the economizer. This type of economizer used in
high percentage of feed water to avoid scaling inside the
tube.
b) Non-steaming economizer:- In this type of economizer
only water flows through the circuit.
Q. What is the draft and types of draft used in boiler?
Ans. The draft is defined as pressure difference in
between a system. There are generally three types of draft
used in boiler,
a) Forced draft: - Here force draft (FD) fan is used to
maintain the draft in boiler. Here the draft inside the
boiler would be always positive draft.
b) Induced drought: - Here induced drought (ID) fan is
used to maintain the draft in boiler. The pressure inside
the boiler would be always negative.
c) Balance drought:- Here both FD and ID fan is used to
maintain the drought inside the boiler. The drought at the
tip of the burner will be zero. This type of drought is used
in maximum boiler.
Q. What is super critical boiler?
A. The boiler which works the pressure above the critical
pressure is known as super-critical boiler. This boiler
works in the principle of once through system. There is no
drum only separator is used for separating steam from
water during partial load
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                                   BOILER QUESTIONS AND ANSWERS

Q. What is (HGI) Hard Grove Index of coal?

Ans. It is the measuring unit through which the hardness of coal
can be determined. Higher value of HGI means coal can be easily
grinded. The HGI of lignite coal is up to 120 where as the HGI of
bituminous coal is 45 to 60 so lignite coal can be easily grinded
than bituminous coal. The HGI is inversely proportional to grinding
power.
Q. What are the factors affecting for a coal mill performance?
Ans. This depend on the no of factors such as,
a) Grindability index of coal.
b) Fineness of coal
c) Moisture content of the coal
d) Size of raw coal.
e) Mill component wear.
Q. What are the advantages of (PF) pulverized coal fired boiler
than the other boiler?
Ans. Here is the advantage of using pulverized coal fired boiler as,
a) Pulverized coal burners act like gas so the fire can be easily
controlled.
b) Cheaper low grade coal can be burnt easily.
c) High combustion efficiency.
d) Load can be varied quickly.
e) Quick and smooth light up of boiler.
f) Flexibility in firing to meet fluctuating load.
Q.What is soot blowers and their types?
Ans. The soot blower is a equipment through which the deposition
of soot in boiler is removed. There are two types of soot blower is
generally used,
a) Steam inject soot blower:- Here the steam is used as the
cleaning medium. The steam flow through a pipe and nozzle,
strikes at the surface of tube and removes the soot. Here three soot
blowers are generally used as i) long retractable soot blower ii) Wall
soot blower iii) Rotary soot blower.
b) Sonic soot blower: - This type of soot blower is used to remove
soot by using low energy and high frequency sounds. They produce
non-destructive sound waves which hit at the surface of tube wall
and remove the deposited soot. By using this type of soot blower
erosion and corrosion of tube can be avoided. Steam loss can also
be avoided. The frequency of sound in this type of soot blower is
ranging from 60 HZ to 350 HZ.
Q. What is foaming of boiler?
 Ans. It is the generation of foam In boiler due to high concentration
of solids, organic matter, bubbles are build up on the surface of
boiler water and passed out with the steam. This is generally
caused due to high concentration of solids in boiler.
 Q. What is priming of boiler ?
 Ans. It Is the carrying amount of droplet water in the steam, witch
leads to carryover of Salt crystals on the super heater and turbines.
priming may be caused due to sudden change of load and
maintaining of high level of water.
Prevention of priming and foaming :- 
The  best  remedy  for  foaming  and  priming carryover  is  the 
proper  blow down  of  TDS.  The continuous   blow down   should  
be   regulated   to maintain  the  TDS  at  3,000  to  4,000  ppm. 
More blow down means less TDS but more blow down is the more
loss of the boiler so the blow down should be within control level.
Q. what is the effect of soot deposits in a boiler?
Ans.
a) The deposited soot act as a poor conductor of heat which reduce
the heat transfer rate and increase flue gas temperature.
b) The deposits block the flue gas path which increase the drought
loss.
c) The deposit may lead to corrosion.
d) Due to falling of large size of soot it damage the tube in dry ash
conveying system.

Q. What are the methods are used for steam temperature

control in boiler.
A. We can control steam temperature by,
a) Using gas recirculation method-Hot flue gas is circulated for
maintain steam temperature.
b) By providing excess air- By providing excess air it reduce the
furnace temperature for some timing hence control temperature.
c) Burner tilting method- Here the tilting of burner are provided by a
pneumatic cylinder. The burner can be tilted 30° up and down for
control temperature.
d) Attemporation control-This is the best method for temperature
control in boiler. Here the attemporator  are provided to spray water
in steam in steam pipe line. Ceramic thermal sleeves are  provided
to avoid thermal shock  due to temperature difference of steam and
spray water.
e) Elevation of fuel firing – The temperature is controlled by
choosing upper or lower elevation of fuel burner.

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                                            TURBINE QUESTIONS AND ANSWERS
Q. what are the Turbine losses?
A. Here are the turbine losses are defined as,
a) Tip leakage loss: - This loss is happen due to small amount of
steam passing in between the clearance of fixed blade and moving
blade. The labyrinths are provided for sealing of fixed and moving
blades.  Some steam passes through this labyrinth clearance 
without any work done.
b) Disc windage loss:- This is the friction loss due to the surface
friction created on the disc.
c)Secondary loss:- This loss is due to friction on the casing wall
and tip of the blade.
d) Wetness loss:- The turbine is designed for 12 % of exhaust
steam. If the wetness of steam increase id absorb the energy due to
water droplets and second thing is it make erosion at the last stage
of the blade.
E) Loss due to lancing wire:- As the lancing wire is provided at
the last stage of turbine blade to provide mechanical strength , the
production of losses in blade efficiency because of passage area
they block.

Q. What is the function of a condenser in turbine?

Ans.
:-It save the DM water as the steam is converted to water and
reuse.
:- It provide high vacuum so that heat rejection takes place from
steam to water.
:- It give space for storage of condensate.
Q. What is dummy / balancing piston in steam turbine?
A. It is one part of the turbine used to neutralizing the axial thrust of
turbine rotor.As the pressure drop at each stage of turbine blade it
produce axial thrust at the same direction of steam flow. So it is
necessary to balance the shaft. It is placed before the first stage of
turbine. This is fixed with the turbine shaft.  The steam enter in
between the balance piston and first stage of turbine and give a
reaction force to the balancing piston opposite to the axial thrust
hence it counter balance the turbine shaft.The diameter of the
balancing disc is designed in a such manner is that it can oppose
the force acting on turbine shaft.
Q. What are the types thrust bearing are used in rotating
machine
A. There are generally four types of thrust bearings are used as,
a) Tapered bearing.
b) Babbitt faced bearing.
c) Tilting pad bearing.
d) Roller bearing.

Q. What is the critical speed of turbine.

A. It is the speed at which the natural frequency of turbine shaft is
close/near  to the operating frequency of the shaft. The turbine shaft
material has its own natural frequency, when we rotate the turbine
rotor at some speed the both frequency are near equal so it
produce a high vibration and noise at this particular frequency. To
avoid critical speed we have to accelerate the turbine speed if the
turbine speed hold at this frequency then a high vibration occurs in
the shaft. The value of critical speed is defined by the designer of
turbine. For example we can say that critical speed of a 150 MW ,
3000 rpm steam turbine may be 1800 rpm , 2200 rpm and 2500
rpm.
Q. What are the couplings used in steam turbine.
A. There are three types of coupling are generally used as,
a) Flexible coupling:- This couplings are used where there is small
misalignment and axial movement of shaft .This coupling require
lubrication.
b) Semi flexible coupling:- These couplings are generally used in
between turbine and generator. No lubrication require for this
coupling.
c) Rigid coupling:- This couplings are  provided in between the
cylinders such as in between HP- LP and between LP- IP
cylinders.  
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                                          TURBINE QUESTIONS AND ANSWERS          

Q. Why turbine kept in turning gear  after shutdown?

A.To avoid hogging (bending downwards) or sagging (bending
upwards) effect of turbine turning gear is used after shutdown .
There is a temperature difference in lower casing and upper
casing of turbine after shutdown if we kept turbine shaft
stationary then it will bent turbine rotor, to avoid this the
turbine should be rotate in slow speed. There are generally
three type of turning gear used ,
a) Electrical turning gear – Electrical motor is used in this type
of turning gear to rotate the turbine less than 30 rpm . A
reduction gear is used to reduce the speed.
b) Hydraulic turning gear- In this system a hydraulic turbine
wheel is mounted on the shaft of the turbine. High velocity oil is
supplied from jacking oil pump which rotate the blade of
hydraulic turning gear hence the turbine rotor. This system will
start after the starting of JOP. Most of advanced turbine use  this
system.
c) Hand barring system – If the electric or hydraulic system fails
then hand barring is done with slow speed through a lever and
handle.
Q. What is turbine stress evaluator (TSE)?
A. It is the instrument used to online  monitor of  turbine
mechanical stress. It calculate the temperature difference of
turbine upper and lower casing. It is the algorithm system based
on the comparison of actual calculated stress.
Q. Why gland steam system is provided in steam turbine?
A.The main function of gland sealing system is , it prevent the
escape/leakage  of steam at the HP side of turbine and prevent
the ingress of air at the LP side of turbine. It is provided at the
turbine shaft. Labyrinth seals are generally used for sealing
purpose. It is generally made of aluminum, bronze and mild
steel. Radial and axial clearance is provided in between the seal.
Steam throttled in every stage and gain kinetic energy at the
expense its pressure energy. So pressure dropped in every
stage and it provide sealing of shaft. By providing the labyrinth
clearance very small the loss can be minimized. Collecting
pockets are provided at other end of sealing in which the steam
can be collected and can be used in gland steam blower.
Q. What is the differential  expansion of steam turbine?
A.  It is the difference of expansion in between the turbine shaft
and turbine casing. The thermal emanation of rotor is happen
because of mass of casing is more than the mass of rotor. This is
happen due to sudden loading of turbine or rate of steam inlet
in turbine is very high. If the rotor expansion is more than casing
then it is known as positive explanation and if the casing
expansion is more than rotor is known as negative
expansion .The expansion value for turbine tripping is generally
provided as +- 6 mm. It is measured by LVDT ( linear variable
differential transducer).
The differential expansion = Change in shaft length into change
in turbine casing length.
Q. What is axial shift of turbine?
A. The axial shift of turbine can be defined as the physical
shifting of turbine rotor from the center point. This shifting is
happen due to thrust on blade of rotor. Thrust tapered bearing
is provided to prevent the axial shift of rotor. The tripping value
for turbine axial shift is generally provided with +- 0.6 mm. The
possible causes of axial shift is due to,
a)Sudden drop in vacuum
b) Sudden drop in steam temperature
c) Sudden change in load
d) Sudden closer of extraction NRV.
e) Lube oil failure in thrust bearing.
f) Scaling in turbine blades.
Q. What is TSE (turbine supervising panel)?
A.This is the integrated combine logic provided to observe the
safe operation of turbine. This supervisory panel observes,
a) Turbine casing explanation during  roiling.
b) Turbine differential expansion.
c) Turbine rotor eccentricity.
d) Turbine vibration.
e) Rate of loading of turbine.

Q. What is over speed of turbine?

A. It is the increased speed of turbine due to grid failure or
islanding condition. Over speed happen due to sudden
unloading of turbine. The over speed of turbine tripping is
generally provided with speed > 110 % of rated speed. The
machine should not be allowed to cross that limit. The over
speed tripping can be provided by a over speed governor or
mechanical governor.
Q. What is turbine tripping condition?
A. A turbine may be tripped due to this reasons,
a) Boiler trip/generator trip
a) Due to over speed- >110 %
b) High axial shift - +- 0.6 mm.
c) High differential expansion - +- 6 mm.
d) Condenser vacuum very low - < 0.6 kg/ cm²
e)  Main steam temperature low - <485 deg c.
f)  Main steam temperature high - > 565 deg c.
g) Press of emergency push button.
h) Main steam pressure and temperature low low and high high.
i) Turbine bearing temperature high- >120 deg c.
g) Turbine vibration high - > 165 micron.
h) Turbine lube oil temperature high - >65 deg c.
i) Mot oil level low - < 30 %.
j) Malfunction of sensing device.

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                            BOILER QUESTION & ANSWER

Q . What is steam trap and it's function?

Ans. function of steam trap- It is a device is used in steam pipe line
to discharge condensate and gasses, prevent to escape of steam
through the line. It ensures that steam is not wasted. This is a self
contained valve which automatically drains the condensate from a
steam containing device. This is generally provided in steam drains
or before steam drain valve.

       You tube video of mechanical steam trap

Types of steam trap:-

1> Mechanical trap – Works in the principle of difference in density
between steam and condensate. This type of trap operate
according the condensate level in the port if the condensate level
increase the float operates and allow to condensate pass through
the pipe ,when condensate level decrease is close the valve and
doesn’t allow the condensate. Types of mechanical trap i) Float
type, ii)Float with lever type, iii)Inverted bucket type, iv)Open bucket
type.
2> Thermodynamic type steam trap - Works in the principle of
difference in between thermodynamic property of steam and
condensate.This types of traps operate due to velocity change in
flow of compressible and non compressible fluids.As the steam
starts condensate there is a temperature difference which allow the
trap to operate. Types of Thermodynamic type steam trap   i) Disc
type ii) orifice type.
3> Thermostatic type steam trap-  This trap works in the principle of
difference of temperature in between  steam and condensate.
Types of Thermostatic type steam trap i) Bimetallic type,       ii)
Metallic expansion type.

Q. What is (NRV) Non Return Valve?

A. This is also known as one way valve which allow the fluid flow in
one direction only. As its name implies non return means there is
only one direction flow.All the assembly are provided with a valve
bonnet.This valves are generally used in pump discharges and
steam water pipe lines.This device ensures there is no back flow of
fluid from the source. It has two lines one is inlet line and other is
outlet line.There is a direction symbol provided on the valve which
show the direction of flow fluid.
Types of NRV:-
i> Tilting disc check valve-This is a disc type check valve.The disc
provided  fixed with a hinge which swing up and down. As the fluid
flow in the line it lift by the fluid force and allow the fluid to flow in
the pipe . When there is no fluid flow in the circuit it closes due to
gravitational force.
ii> Ball check valve- Here a spherical ball is used to fervent the fluid
flow. The ball is spring loaded which close the valve when there is
no fluid flow in the line. The pressure of fluid lift the ball and let the
fluid to flow.
iii> Diaphragm type NRV – This is consists of a rubber diaphragm
clapper ,Which works on the differential  pressure When the
pressure in the upstream is more it open the diaphragm and allow
the fluid to flow and when the pressure is equalize is closes
diaphragm and prevent to fluid.
iv> Stop check valve- It’s construction is same as the swing check
valve except that here is a external control mechanism of handle or
lever provided.
v> Lift check valve- Here a lift or disc is provided which operates on
the working pressure of the fluid.

Q. what is Pressure relief valve(PRV) ?

A.

                                    

                                           Image of pressure relief valve.

The relief valve (PRV) is a type of valve used to control or limit the
pressure in a vessel or system during an overpressure of the
system. The primary purpose of a pressure Relief Valve is
protection of life and property by venting fluid from an over
pressurized vessel. Many electronic, pneumatic and hydraulic
systems exist today to control fluid system variables, such as
pressure, temperature and flow. Each of these systems requires a
power source of some type, such as electricity or compressed air in
order to operate. A pressure Relief Valve must be capable of
operating at all times, especially during a period of power failure
when system controls are nonfunctional. The PRV is provided on
the on the main steam line to control the line pressure. The PRV is
generally operated through pneumatic pressure.The  PRV operated
according to the set pressure of rhe controller. The valve set down
when the pressure reach to normal value.

Q. What is the difference between safety valve and pressure

relief valve?
A. Difference between safety valve and relief valve
Relief Valve –The  relief valve is used on a filled vessel. For such a
valve the opening is proportional to increase in the vessel pressure.
Hence the opening of valve is not sudden, but gradual if the
pressure is increased gradually. A relief valve is meant to relieve
pressure to prevent an over pressure condition.  A relief valve may
have an operator on it to assist in opening the valve in response to
a control signal. The capacity of PRV are generally small.
Safety Valve – This device is used to  relief on a compressible filled
vessel. For such a valve the opening is sudden. When the set
pressure of the valve is reached, the valve opens almost fully. A
safety valve is meant to relieve pressure without operator
assistance and a safety valve, or combination of safety valves, must
be have a capacity to relieve more than the energy input to the
volume being protected.  

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