20+ Boiler DCS Engineer Interview Questions and Answers

To monitor and control the oxygen levels in the flue gas between the economizer and air preheater.

• Installing an O2 analyzer between the economizer and air preheater helps optimize combustion efficiency.

• It allows for real-time monitoring of oxygen levels in the flue gas, enabling adjustments to the air-to-fuel ratio.

• Maintaining the optimal oxygen levels ensures complete combustion and reduces fuel consumption.

• By controlling the oxygen levels, it helps minimize the formation of...read more

APH leakage is a problem in boilers that can lead to reduced efficiency and increased emissions.

• APH stands for Air Preheater, which is used to heat the combustion air before it enters the boiler.

• Leakage in the APH can result in loss of heat and reduced efficiency.

• Identifying the leakage involves inspecting the APH for visible signs of damage or leakage, conducting pressure tests, and monitoring performance parameters.

• Common causes of APH leakage include worn-out seals, corros...read more

Pressure drop from boiler drum to superheater is due to the decrease in steam density and frictional losses.

• Pressure drop occurs due to the decrease in steam density as it passes from the boiler drum to the superheater.

• Frictional losses also contribute to the pressure drop.

• The pressure drop is necessary to ensure proper steam flow and temperature control in the superheater.

• Factors such as pipe length, diameter, and bends can affect the magnitude of pressure drop.

• Proper design...read more

Maintaining above 120 degree ESP temperature is important for efficient operation and prevention of corrosion.

• Higher ESP temperature ensures efficient removal of particulate matter from flue gas.

• It helps in preventing corrosion of the ESP components.

• Maintaining temperature above 120 degrees ensures optimal performance of the ESP system.

• Lower temperatures can lead to reduced efficiency and increased maintenance requirements.

• Examples of ESP components that can be affected by lo...read more

Safety equipments are necessary to prevent accidents and injuries in the workplace.

• Safety equipments provide protection against potential hazards and risks.

• They can minimize the severity of injuries in case of accidents.

• They can also prevent accidents from happening in the first place.

• Examples of safety equipments include helmets, safety glasses, gloves, and safety harnesses.

• Using safety equipments is a legal requirement in many industries.

• Proper training and maintenance of s...read more

There are eight types of losses in a boiler.

• The eight types of losses in a boiler are: radiation, convection, exhaust, blowdown, incomplete combustion, unburnt fuel, ash, and moisture.

• Radiation loss occurs due to the heat radiated from the boiler's surface.

• Convection loss occurs due to the heat carried away by the flue gases.

• Exhaust loss occurs due to the heat carried away by the exhaust gases.

• Blowdown loss occurs due to the removal of hot water and steam from the boiler.

• Inco...read more

Boiler commission activity refers to the process of testing and verifying the functionality of a newly installed boiler.

• Boiler commissioning involves a series of tests to ensure that the boiler is safe, efficient, and meets regulatory standards.

• Tests may include checking the fuel and water supply systems, verifying the control system, and testing safety features.

• Commissioning also involves training operators and documenting the results of the tests.

• Examples of commissioning a...read more

The O2 analiger in a boiler is typically located in the flue gas stream.

• The O2 analiger is used to measure the oxygen content in the flue gas.

• It is important to monitor the oxygen levels in the flue gas to optimize combustion efficiency.

• The O2 analiger is usually installed in the boiler's flue gas duct or stack.

• It may be located at a specific distance from the boiler outlet to ensure accurate measurements.

• The O2 analiger may have a probe that extends into the flue gas stream ...read more

Drum pressure drops in the area of steam generation and distribution.

• Drum pressure drop can occur due to steam leakage in the distribution system.

• Pressure drop can also happen in the steam generation process, such as in the boiler or heat exchanger.

• Other factors that can cause drum pressure drop include fouling or scaling in the system.

• Monitoring and maintaining proper drum pressure is crucial for efficient and safe operation of the boiler system.

Types of losses in Boiler

• Heat loss through flue gases

• Heat loss through radiation and convection

• Incomplete combustion losses

• Blowdown losses

• Ash and unburnt losses

Sensible heat refers to the heat that causes a change in temperature without a change in phase.

• Sensible heat is the heat energy that can be sensed or measured by a thermometer.

• It is the heat that causes a substance to increase or decrease in temperature.

• Sensible heat does not result in a change of state or phase.

• For example, when ice is heated and melts into water, the heat absorbed during this process is sensible heat.

• Sensible heat is important in the operation of boilers as...read more

The boiler efficiency in AFBC boiler depends on various factors such as fuel quality, combustion efficiency, heat transfer efficiency, and excess air levels.

• Boiler efficiency in AFBC boiler is typically in the range of 75-85%.

• Factors affecting boiler efficiency include fuel quality, combustion efficiency, heat transfer efficiency, and excess air levels.

• Regular maintenance and tuning of the boiler can help improve efficiency.

• Efficiency can be calculated using the formula: Effi...read more

Efficiency is the ability to do something in a way that achieves maximum productivity with minimum wasted effort or expense.

• Efficiency is a measure of how well a system or process performs.

• It is often expressed as a percentage of the total input that is converted into useful output.

• For example, a car's fuel efficiency is measured in miles per gallon (MPG).

• Efficiency can be improved by optimizing processes, reducing waste, and increasing productivity.

• Efficiency is important in...read more

Latent heat is the heat energy absorbed or released during a phase change without a change in temperature.

• Latent heat is the energy required to change the state of a substance without changing its temperature.

• It is the heat energy absorbed or released during processes like melting, vaporization, and condensation.

• During phase changes, the energy is used to break or form intermolecular bonds.

• Examples include the heat absorbed when ice melts into water or the heat released when ...read more

Types of losses in a boiler system

• Heat loss through walls and pipes

• Incomplete combustion of fuel

• Blowdown loss

• Radiation loss

• Stack loss

• Excess air loss

Boiler emergency handling involves immediate actions to prevent accidents and ensure safety.

• Shut down the boiler to prevent further damage

• Isolate the boiler from other systems

• Notify relevant personnel and authorities

• Implement emergency procedures and protocols

• Evacuate personnel from the area if necessary

To handle a blackout or equipment trip, follow proper shutdown procedures, isolate the affected equipment, investigate the cause, and take necessary corrective actions.

• Follow proper shutdown procedures to minimize damage and ensure safety.

• Isolate the affected equipment to prevent further damage or accidents.

• Investigate the cause of the blackout or equipment trip to identify the root cause.

• Take necessary corrective actions to fix the issue and prevent future occurrences.

• Exampl...read more

Boiler smooth operating mode ensures efficient and safe operation of the boiler system.

• Regular maintenance and inspections are key to ensuring smooth operation.

• Proper fuel and air mixture is essential for efficient combustion.

• Monitoring and controlling parameters such as pressure, temperature, and flow rates is crucial.

• Implementing safety protocols and emergency shutdown procedures is important.

• Utilizing advanced DCS systems can help optimize boiler performance.

I have experience troubleshooting boiler issues such as leaks, pressure fluctuations, and burner malfunctions.

• Identifying and repairing leaks in boiler tubes or fittings

• Investigating and resolving pressure fluctuations in the boiler system

• Troubleshooting burner malfunctions and adjusting settings as needed

Heat rate coal consumption is the amount of energy produced per unit of coal consumed.

• Heat rate is measured in British thermal units (BTUs) per kilowatt-hour (kWh).

• A lower heat rate indicates greater efficiency in converting coal to electricity.

• Factors affecting heat rate include boiler efficiency, turbine design, and coal quality.

• Monitoring and optimizing heat rate can lead to cost savings and reduced emissions.

• Example: A power plant with a heat rate of 10,000 BTU/kWh would ...read more

The startup procedure for a boiler involves several steps to ensure safe and efficient operation.

• Check all valves and switches are in the correct position

• Ensure proper fuel and water levels are maintained

• Purge air from the system before igniting the burner

• Monitor pressure and temperature levels during startup

• Perform safety checks before putting the boiler into operation

DCS stands for Distributed Control System.

• DCS is a computerized control system used to control and monitor industrial processes.

• It consists of a network of controllers distributed throughout a plant or facility.

• DCS allows for centralized control and monitoring of various processes and equipment.

• It provides real-time data acquisition, control, and visualization.

• Examples of DCS include systems used in power plants, oil refineries, and manufacturing plants.