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628 Cards in this Set
- Front
- Back
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How much clearance from the top of the boiler is needed for a HP boiler that produces 70000 lbs of steam?
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7 feet
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On a gas fired boiler what is the proper gas to air mixture
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30%-70% and in special arrangements it can be as high as 100% . ANSWER CHAPTER 11 remember%
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What is the total hardness in a system that was found to have calcium hardness of 60ppm and magnesium hardness of 18ppm and carbon hardness of 12 ppm?
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TH=(Ca x 2.5) + (Mg x 4.1)
TH=(60 x 2.5) + (18 x 4.1) TH= 150+73.8 =( 223.8 PPM) |
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How often should a complete external inspection of the boiler be done?
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Once a Shift
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With 24 hr operation how often do you check the water level?
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Once per shift
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How often do you check the LWCO?
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Once per shift
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How often do you check the High Limit Switch?
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Annually
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A 2” pipe was found to be delivering water at 100 psia at 1040ft per second. How many gallons per hour will it deliver?
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GPM= V (diameter squared) divided by .4085 ANSWER pg 469 BOG
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What controls the amount of blowback on a safety valve?
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Blowback ring or adjusting ring
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On a open air expansion tank hot water boiler system; how high should it be mounted?
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(4 Feet ) above the highest heating element.
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What is the minimum top clearance of boilers with manholes?
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5 feet
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Package boilers; steam heating boilers and hot water heating boilers shall have a minimum clearance of?
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2 feet from ceiling. Code chapter 10 page76
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Most important safety device on a boiler?
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Safety relief valve
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What does a Black Liquor Boiler do?
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Black Liquor is the by product of wood pulp processing in the paper making industry.
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What does Black liquor boiler known for?
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Steam generation and recovery of soda ash
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Maximum line voltage for control on a boiler?
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150 volts
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Under what code are boilers designed and constructed?
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ASME- CSD 1
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How many low water cut offs are needed per code for a hot water system when a boiler has inputs greater than 400,000 btu per hr
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1 LWCO is needed.
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What is the minimum and maximum size for a safety valve per code for boilers?
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Minimum 3/4” and Maximum 4 1/2”
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What stamp is put on a boiler after repairs?
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“R”
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What is the equalizing system used for?
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The equalizing system is for warming up the steam lead.
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A blowdown valve is located at the lowest water space of a boiler for three purposes
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1. to remove precipitated sludge or loose scale
2. To permit rapid lowering of the boiler water if it has become too high accidentally 3. As a means of removing water from the boiler so that fresh water may be added to keep the concentration of solids below the point where difficulties may be experienced. |
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In the old power boiler which type of feed-water regulators were not used?
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Electronic
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After opening a boiler for repairs how much oxygen is needed?
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19%
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What is the first thing you do when shutting down a boiler?
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Turn off (extinguish fire)
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What is the legal limit of acceptable asbestos particles ?
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0.1 fibers per cubic centimeter
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What is CREEP?
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Creep is defined as the slow deformation of material with time; with the deformation taking place at elevated temperatures with no increase in stress.
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What is the BTU content of Anthracite coal?
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14000 btu/lb
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What substance transfers electrical current in a photocell?
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Electricity will flow when the CADMIUM is exposed to sufficient light.
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What device acts as a check valve in both directions and keeps pumps primed?
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FOOT VALVES are used for pumps under suction pressure to prevent backflow primed? on the suction line.
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What protects boilers from explosion in the furnace?
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A flame guard system is an arrangement of flame detection system; interlocks; and relays which will sense the presence of a proper flame in a furnace and cause fuel to be shut off to the furnace if a hazardous condition develops (improper flame or combustion).
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What size pipe is used as a header in a boiler operating at 100psi?
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6 inches
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What device is used to measure flue gasses
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The Orsat Analyzer
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Which low water cut off does not have a mercury switch?
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The Submerged electrode type
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What is the btu output per lb of #4 fuel oil?
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18
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What substance is used for the electric transmission in an RTD?
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Platinum is used because of its stability at high temperatures
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How much air is needed for the combustion of pulverized coal; gas; oil?
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50% for coal and 10-30% for gas & oil
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In old power boilers which type of feedwater regulators were not used?
(A) hydraulic (B) float (C) thermostatic expansion (D) electronic |
ANSWER D electronic/electro-magnetic
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What is hard forming scale?
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Silica
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With hydroxide present and normal oxygen levels which chemical will cause problems?
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Chlorine
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The result from steel manufacturing and under pressure in boilers tends to cause buldging? A buldge is caused by ?
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A buldge is caused by overheating of the shell plates and it affects the entire thickness of the plate.
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A blister is caused by what ?
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Slag inclusion forming a lamination at the time the plate was rolled at the steel mill. A blister is a separation of the metal from the shell plate caused by impurities rolled into the shell plate when formed.
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With normal oxygen and low alkalinity. what is added to the boiler water?
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Neutralizing Amines
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Which chemical is used to combat scale?
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Combined phosphate treatment- sodium phosphate
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Other than sulfite what chemical is used to combat corrosion in boilers?
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Hydrazine
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What will neutralize acid?
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Alkali and Lime Soda
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What mechanical device is used to remove scale from firetubes?
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A tube rattler or vibrator
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What percentage of the pressure should a boiler have before you test the lever of a safety valve?
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75%
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Where is internal corrosion most likely to occur on a vertical tube boiler?
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Water leg-Mud leg
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What are the minimum and maximum sizes permitted for blow down valves or connections?
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3/4"minimum 2 ½ “ maximum
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A boiler operating at a pressure of 65lbs. What is the smallest size feed and blow off connections if the safety valve is set at 90 psi?
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½ “ feed ¾ “ blow off
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How often should water columns and water glass levels be checked on a high pressure boiler?
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(Once A Shift)
At the beginning of each shift - beginning of the work effort |
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What takes no actual action chemical part in combustion?
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Nitrogen
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How many ppm of EDTA are needed to tie up 1ppm of hardness?
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EDTA requires 10ppm of EDTA and 5 NTA to tie up each 1ppm hardness.
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On a package boiler; how many ways could cause fire puffs when it is started up?
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6 ways 1-poor starting draft 2-incorrect firebox 3-wrong burner nozzle 4-lean fire 5- insufficient gas pilot or excessive gas pilot 6-water in the oil
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What is the grade of light domestic fuel oil ?
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Grade 1 ( Number 1 )
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How often should you test the operating control?
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Annually
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How often should the testing and inspecting of the burner component?
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Annually
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A lead sulfite photocell is what type of flame sensor?
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Infrared light sensing
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What is the least amount of oxygen needed when a nitrogen blanket is used?
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19%
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How should a boiler be prepared for inspection?
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Extinguish fire and allow boiler to cool slowly. Open the blow down and the drain; vent the boiler to the atmosphere Soot and ashes should be removed from all tubes; shell plates; heads; seams and every accessible external surface. The blow down should be shut if any other boiler feeds this line. Manhole - handhole plates and inspection plugs should be removed. All loose deposits of sludge or sediment should be washed out. The blow down should only be opened when it is certain that there is no pressure in the line and no one is inside the boiler. Any scale or oil deposits should be left for the water treatment specialist to see for analysis. A boiler properly prepared for inspection should be cool; dry and clean. It is advisable to attach a red tag marked “person in boiler” to the steam; blowdown; feed and fuel valves and also to the manhole plate whenever someone is inside a boiler.
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What function can a boiler operator contribute to boiler maintenance?
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A) maintain a safe reliable plant B) maintenance and efficient plant C) Inspection and logging of items that need to be corrected during the next maintenance period
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What are manholes and handholes on a boiler for?
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Examination or cleaning
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How do you protect a steam boiler?
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Safety valve
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How to you protect a pressure vessel?
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Pressure relief valve
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How do you protect a hot water boiler?
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Pressure relief valve
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What gages are on a steam boiler?
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Water gage glass and pressure gage
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Methods used to control the temperature of a superheater?
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Bypass damper - spray-type desuperheater - attemperator - condenser - tilting burner - flue gas recirculation
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What chemical would you use to prevent hard scale from forming in the boiler tubes?
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Disodium phosphate and trisodium phosphate
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What chemical compounds in water cause permanent hardness?
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Calcium sulfate and magnesium sulfate
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What factors must be taken into consideration when choosing a control for a boiler?
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6 factors 1. Steam pressure 2. Furnace pressure and draft 3. air pressure and flow 4. feed water pressure and flow 5. Flue gas flow & composition 6. proper ignition & burner - flame control
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How many safety controls shut down a boiler when an unsafe condition occurs?
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7 controls 1. Pressure limit or temperature 2. Low water fuel cutoffs 3. Flame failure safeguard systems 4. Automatic ignition controls 5. oil and gas fuel shutoffs/valve controls 6. air and fuel pressure interlock controls 7. feed water regulating controls
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In a steam generating system what is blamed on chemical treatment but is in fact part of a boiler design?
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Poor circulation
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Class A Fires???
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Wood - sawdust - paper - rags
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Class B Fires??
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Flammable liquids - oils - tars and gasses
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Class C Fires??
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Electrical equipment
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What is the minimum clearance required when a boilers capacity is 5 000btus hr over 1000sq ft heating surface or an imput over 5 000 000 btus hr?
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7 feet
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Under what code are oil fired boilers and their control systems covered?
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O.F.B 726
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A data plate has what information??
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manufacturer - model serial number - stamp of approval
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When working in a boiler work permits should be aquired when?
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For Each Shift
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ASME code requires that a LWCO control be tested by evaporation how often??
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Monthly
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ASME CSD1 requires the main gas burner to have what?
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2 manual shutoff valves. pg 81 1004.1 code book
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A HYDROSTATIC test is done at what pressure?
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1.5 times the MAWP or 50% over MAWP
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How many low water cutoff are needed per code on a hot water system?
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One LWCO is needed when the boiler input is greater than 400 000 btus
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What gages are on a steam boiler?
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pressure gage - water gage glass
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What gages are on a HW boiler?
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pressure - Temp
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Name three types of low water cutoffs.
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1. float magnetic (rod to magnet to mercury switch) 2. Float linkage- link to mercury switch 3. Submerged electrode- water
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Boilers having more than 500square feet of heating surface should have how many means of feed water?
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2
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Types of FEEDWATER REGULATORS
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1.Thermostatic mechanical regulator 2. Thermostatic fluid style 3. Float operated style
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Name two types of commonly used feedwater pumps
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Injector and Inspirator
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What piping arrangment is used to return condensate from steam lines and steam seperators?
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HOLLYLOOP
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What would happen if high temp liquid passes through a centrifugal pump?
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WIRE DRAWING
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A multi stage pump can be either __________ or_______ ?
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Volute or Diffuser
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To prevent cavitation most pumps are stamped with the ____ _______ _______ ____ ?
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NET POSITIVE SUCTION HEAD
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What are two types of condensate return systems??
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a.) Mechanical Return ; uses steam traps and pumps to aid return b.) Gravity Return System : uses gravity
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TO PREVENT THE SUPERHEATER FROM OVERHEATING ON START UP WHAT SHOULD YOU DO
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EITHER FLOOD THE TUBES WITH WATER OR THE SUPERHEATER SHOULD BE VENTED TO THE ATMOSPHERE BY A FREE BLOW VALVE UNTIL THE BOILER GOES ON LINE.
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What device acts as a check valve in both directions and keeps the pump primmed?
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FOOT VALVES ARE USED ON PUMPS UNDER SUCTION PRESSURE AND PREVENT FLOW ON SUCTION LINE
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WHAT PUMP HAS A WATER PISTON DIRECTLY CONNECTED TO A STEAM DRIVEN PISTON VIA A ROD?
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RECIPRICATING
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What causes a piston type trap to open?
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cold condensate (on test the steam psi drop and temp drop was used)
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Quickly opening a steam valve will cause _______ ________ .
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water hammer
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What mechanical device removes scale from a watertube boiler?
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a tube turbine
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What causes blistering?
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A slag inclusion forming a lamination at the time the plate was rolled in the steel mill and it's actually a seperation of metal from the shell plate caused by impurities rolled into the shellplate when it was formed.
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To internally remove oxygen from the boiler use______ ________ .
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Sodium Sulfite
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A positioning control system is used on a ______ ________
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a process boiler
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A saybolt universal is a
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measurement of viscosity
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Creep gets worse with _______________ __________
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elevated temps
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What type of valve WOULD NOT be a good choice if sediment were present
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GLOBE
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How many btus does it take to take 10 lbs of steam from 40 to 41 degrees
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10 btus 1btu=1lb
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What is it called when you let a peice of equipment fail before you repair/replace it?
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Breakdown maintenance
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What percent of blistering or buldging is ok?
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2%
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What kind of boiler are staybolts found on?
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Fire tube boilers
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A 8 foot length of tube or shell can take up to ___% sag or bend and still be used without replacing?
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2%
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What does a low water cutoff do in a low water condition?
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Shuts off fuel supply
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What is the first indication of a low water condition
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A red hot crown sheet
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If a boiler exceeds 100psi it must have how many blowdowns?
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2
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What is the appropriate test for checking porosity of the metal?
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PULSE ECHO ( A TYPE OF ULTRASONIC)
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What chemicals are used to combat corrosion?
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Sodium Sulfite; hydrazine; catalied hydrazine
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If your boiler water has a PH of .5 what compound type do you add to neutralize it?
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BASES - THEY REACT WITH ACIDS TO FORM A SALT
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What level of deionized water alkalinityis permitted for a 600 psi boiler?
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250 PPM
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What can oxygen cause in a system
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PITTING CORROSION
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In a vertical boiler where is the first place to check for thinning tubes?
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WATER LEGS especially at the bottom or on the combustion side at the upper ends of the tubes.
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What produces soft scale?
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Calcium and magnesium carbonate and magnesium clorine
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Hideout in a boiler causes what to precipitate?
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Sodium phosphate
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What is main cause of a generating tube failure?
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overheating at the lower tubes due to scale sludge and poor circulation
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What refrigerant is flammable and non toxic ?
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Propane
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What refrigerant class is Ammonia R 717?
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B2
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What is the purpose of a condensor in a refrigerant system?
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to bring refrigerant to a liquid state
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Why is oil in a refrigerating system?
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lubricates and cools compressor
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How is moisture removed from a refrigerant system?
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filter dryer
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What type of gas DONT you use to leak test an AC system?
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OXYGEN
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What is the maximum voltage on a boiler control circuit?
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150 VOLTS
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A fuel oil that has an API of 32 has how many btus per lb of heating?
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19490
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Which fuel oils need heating?
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#4;#5;#6
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What size pipe is used as a header in a boiler operating at 100 psi?
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6 inches
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What function can an operator contribute towards boiler function?
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saftey - efficiency - log plant readings
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How is heat transferred in a boiler ?
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CONVECTION - CONDUCTION - RADIATION
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What is not an organic sludge conditioner?
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Amines
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Which by-product has the largest heating value?
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Butane
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An increase in 10-20 degrees can reduce creep life by how manuy years
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10-20
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which coal burns with a yellow flame?
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Bituminous
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What nondestructive testing is best for testing thickness of plates and tubes?
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Ultrasound
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On a 2"valve auxillary staem what valves are needed?
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Single supply OS&Y
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What are the min and max size of a safely valve per code for boilers?
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Min 3/4 and max 4 1/2
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What stamp is put on a safety valve after its been repairs?
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VR stamp
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How often do you test your float controls on a hot water boiler?
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Weekly
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How often do you test a safety valve with pressure?
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Annually
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How often do you test a safety valve with a lever test?
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Monthly
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This part of the safety valve works in conjunction with the adjusting ring to allow it to pop open.
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Huddling Chamber
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What do you do if a safety valve is leaking?
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Reground seat
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A safety valve discharge pipe should go how high when workers maybe present?
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6 feet high
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If 2 safety valves are used with the same discharge pipe the discharge line must have
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The same area as both valves area
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Every discharge valve should have what size drain?
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3/8 to 1/2 drain
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What are the Blowback setting on a safety valve?
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Up to 4% but not less than 2 lbs
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Safety valve plate has;
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Manufacturer's name or trade mark- type or design# - Size - seat dial - set pressure -blowdown - Discharge capacity lb per hr - capacity lift - AMSE symbol or NB stamping.
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What percentage of boiler pressure is needed to hand check a boiler safety valve?
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75%
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On an open air expansion tank hot boiler system; How high should it be mounted?
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4 feet above the highest heating element.
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What is the minimum clearance of boilers without manhole covers on top?
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2 ft
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Under what code are oil fired boilers & their control systems covered?
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Listed & labeled in accordance with UL 726.NFPA 8501
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How high is a pull station mounted on a wall?
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48 inches
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When working in a boiler; work permits should be acquired?
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For the work shift.
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To inspect a boiler they must be what?
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Be employed either by the state or by an insurance company licensed to write boiler and pressure vessel insurance in that jurisdiction
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ASME CSD 1 requires the main gas burners train to have what?
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2 manual safety shutoff valves
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Welds must be approved and witnessed who?
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Authorized inspector.
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Hydrostatic test is done at what pressure?
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1.5 times the MAWP or 50% over MAWP
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During a hydro test if the boiler leaks who do you notify?
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Authorized boiler inspector and they will advise you what to do.
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How many low water cut offs are needed per code for hot water boiler systems?
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When the boiler has an input greater than 400 000 BTU’s per hr 1 L.W. cutout is needed
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What are the minimum and maximum sizes permitted for blowdown valves or connection?
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1 min & 2-1/2 max
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If a boiler has 1" blow down pipe; what diameter should the boiler blow down tank air vent should be?
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2.5"
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What are 3 low water cutouts?
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(Float magnet type - it has a plunger on a float rod an a permanent magnet with a mercury switch) (Float-linkage type- a linkage connected to a mercury switch) (Submerged-electrode type- uses an electrode make the complete burner circuit)
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What does a low water cut out do in a low water condition?
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Shuts off the fuel supply when it drops below the visible level
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Boiler that exceeds 100 psi must have how many blow downs
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TWO
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How many times the safety valve setting should the pressure gauge be?
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1-1/2 to 2 times
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When blowing down the water column you notice the gauge glass slowly returns to the normal level; this could be indication of what?
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The bottom of the gauge glass is clogged and giving a false reading
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How many inches should the lowest visible level in the gauge glass be in a boiler?
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TWO inches
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What are the minimum gauge glass connection and drain?
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1/2 connection and 1/4 drain
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What must be done if the gauge glass cannot be seen from the operating area?
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There must be 2 independent remote level indicators installed.
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Blowdown shall not be less than __ or lower than __ of the safety valve?
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Less than 2 lbs or lower than 96% of the safety valve
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Blow down valves fitting should be designed at least __ % greater pressure than the MAWP?
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25%
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What are two types of commonly used feed water pumps
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Injectors and Inspirator
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How does steam flow through pipes?
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Larger diameter slower the flow Smaller diameter higher velocity - Pressure difference draws flow
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An acid is a compound that yeilds ________ ions and has a pH value lower than 7.
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hydrogen
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A base is a compound that yields __________ ions and has a pH value greater than 7.
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hydroxyl
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A _________ is a gelatin like sustance that has very small particles in suspension. These particles are usually less than ___ microns in size.
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colloidal 0.2
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One grain is equal to ______ parts per million. ________ grains equals one pound.
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17.1 ; 7000
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A solid that is separated from a solution is a_________________.
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precipate
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All impurities are in one of four states
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they are ________; __________; _________; and _________.
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The capacity of a substance to combine with another substance is its _____________.
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Valence
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Calcium and Magnesium bicarbonate produce ___________ hardness.
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temporary
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Scale that is soft and muddy simular to magnesium carbonate is___________________.
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calcium carbonate
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In order to prevent corrosion
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boiler water pH is maintained between ________________.
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__________ _________ is used to internally remove oxygen from the boiler.
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sodium sulfite
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In order to remove one pound of oxygen
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it takes ________ lbs of sodium sulfate.
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__________ are added to the boiler to prevent steam line and condensate line corrosion. These chemicals are used because they will blow off with the steam.
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amines
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When boiler water has high levels of solids; steam bubbles can be trapped below the water line causing water level fluctuations known as __________.
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Foaming
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___________ is when water impurities leave the boiler with the steam.
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carryover
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The loss of metal that forms smooth
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rolling contour as a result of an acid attack is called __________.
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__________ blowdown lowers the TDS level in the boiler.
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surface
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The electrolytic flow between dissimilar metals in a waterborne environment which results in localized corrosion is known as _____________.
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galvanic action
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The_______ _______ or______ _______ _______ sense heat to prove flame in a boiler.
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Stack switch - rectifying flame rod
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Rectifying phototubes and cadmium sulfide phototube both prove flame in the boiler by sensing __________ ________.
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Visible light
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The chief heat producing elements in fuels are_____; ______ and__________.
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carbon hydrogen sulfer
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|
|
The presence of _________ in flue gas is an indication of incomplete combustion.
|
Carbon monoxide
|
|
|
The EPA limits the amount of particulate emission to ________ pounds per 1 000 000 btu's input.
|
.10
|
|
|
When NOx combines with organic gases ________ is produced.
|
Ozone
|
|
|
Anthracite coal is very hard and has a high percentage of fixed________ and a heating value of ________btu's per pound.
|
fixed carbon - 14000
|
|
|
__________ is the lowest grade of coal; has a claylike appearance and a heating value range of _______ to _______btu's per lb.
|
Lignate 7000 to 11000 btu's per lb
|
|
|
Spreader and chain grate stokers are types of ___________ stokers
|
over feed
|
|
|
#2 fuel oil is classified as _________ domestic fuel oil.
|
medium
|
|
|
#6 fuel oil is also known as??
|
Bunker C
|
|
|
#4 fuel oil has about________ btu's per lb.
|
18
|
|
|
Which fuels require heaing prior to being sprayed into a furnace?
|
4;5;6
|
|
|
As the temperature of a fuel oil rises; the visosity goes_____.
|
Down
|
|
|
What burner can burn almost any fuel at any temperature??
|
steam atomizing
|
|
|
Steam atomization typically consumes about ____ percent of the steam produced by the boiler.
|
2%
|
|
|
An air atomizing burner requires______psi air pressure above the oil pressure when burning heavy oil.
|
20
|
|
|
Flame impingment on the metel surfaces of the boiler can cause the metal to ______ and ______.
|
overheat; bulge
|
|
|
Obstructions in the combustion airflow path can lead to a rich fuel air mixture; which can lead to _______ coming from the stack.
|
smoke
|
|
|
For proper combustion air into the boiler room
|
one square inch of outdoor air opening is required per _______btu/hr input.
|
|
|
Natural gas has a heating value of ______btu's per ft3 or _________________ btu's per therm.
|
1000 btu per ft cubed or 100 000btu's per therm
|
|
|
Coal gas is produced from the volitile matter from______ coal and has a heating value of_____bu's per cubic foot.
|
Bituminous; 550btu's per cubic foot
|
|
|
Propane has a heating value of________btu's per cubic foot.
|
2500
|
|
|
Butane has a heating value of________btus per cubic foot.
|
3200-3260
|
|
|
The type of fuel gas with the lowest btu content is _____ ______ gas and it has ______ btus per cubic foot.
|
Blast Furnace; 90 btu per cubic foot
|
|
|
Sewage gas contains about 2/3 methane and 1/3 carbon dioxide. The heating value is about _____ btu per cubic foot.
|
650
|
|
|
The momentum of the low pressure gas is used to draw the air required to complete the combustion process in an _________ burner.
|
Atmospheric burner
|
|
|
Atmospheric burners have _________ to ________ percent pre-mixing of natural gas and air.
|
30 % to 70%
|
|
|
Infared flame scanners use a ____________ __________ cell to detect the presence of a flame.
|
Lead Sulfide
|
|
|
Unlike an infared scanner; the ultraviolet scanner is not affected by light given off by hot________________.
|
Refractories
|
|
|
What is the circumference of a circle with a 6" diameter?
|
c=dx3.14
|
|
|
How do you find the area of a circle?
|
A=Dsqared X .7854
|
|
|
Diameter of circle
|
D=2 X Radius
|
|
|
Name four types of corrosion
|
1. fretting 2. galvanic 3. crevice 4. localized
|
|
|
degree F to degree C
|
C=(F-32)/1.8
|
|
|
C to F formula
|
F=(C X 1.8)+32
|
|
|
GPM formula
|
GPM=VxDsquared/.4085
|
|
|
Capacity formula
|
GPM=LANE/231
|
|
|
A steam pressure guage has a _____ to protect against the high _________ of the steam.
|
siphon - temperature
|
|
|
A cross or tee connection to the boiler drum used eclusivly for attaching a test pressure guage is known as
|
inspectors connection
|
|
|
A ________thermometer uses two dissimilar metals that bend predictably with a change in temp.
|
BIMETALIC
|
|
|
Minimum size for the connection between the guage glass and the water column is _______
|
1/2"
|
|
|
2 or more saftey valves are required on a boiler with a heating surface inexcess of ______square feet or electric imput of ________KW
|
500 sq ft ; 500KW
|
|
|
Safetey valves on a superheater should be set _____than the safety valve on the steam drum
|
lower
|
|
|
Boiler stop valves over 2 inches in diameter should be ___ _______ ___ ______.
|
OS&Y
|
|
|
When boiler pressure exceeds _____psi; two blowdown valves must be used; one must be a slow opening valve
|
100
|
|
|
Slow opening blowdown valves must complete ___turns between full open and full shut.
|
5
|
|
|
A COPES feedwater regulator is an example of a ________ ____________type feedwater regulator.
|
thermostatic mechanical
|
|
|
The feedwater control valve position is controlled by the _______ of the fluid as caused by the temp changes caused by water level changes in the thermostatic tube
|
PRESSURE
|
|
|
The 3 element feedwater regulator senses ________ _________ AND_________.
|
steam flow - feedwater flow - and water level
|
|
|
The _______ ________uses boiler water to complete the electrical circuit
|
submerged electrode
|
|
|
The submerged electrode does not have a __________ _______.
|
mercury switch
|
|
|
2 types of electric boilers
|
RESISTANCE and ELECTRODE
|
|
|
Electric current flows through the water and converts electrical energy to heat energy in the ________type boiler
|
ELECTRODE
|
|
|
A high voltage steam electrode has voltage between _____ AND_________
|
2300 and 15000 Volts
|
|
|
A high voltage steam electrode boiler has ___ generating compartments; one for each phase.
|
3
|
|
|
The capacity of a safety valve on an electric boiler is __ lbs per KW or ___ btus per hr per KW
|
3.5 LBS - 3500btus per KW
|
|
|
An HTHW system has better temp control becauase it has a large _______ _______ ________.
|
heat storage capacity
|
|
|
Downtherm thermal liquid systems use ________ _____________ at tubes to prevent leaking
|
welded joints
|
|
|
__________ ________ boilers recover heat in the exaust from a gas turbine to produce usefull steam
|
WASTE HEAT
|
|
|
When exaust gasses dont have enough energy to produce the final steam pressure _______ ________ is used.
|
SUPPLEMENTAL FIRING
|
|
|
A recovery steam generator converts steam energy to mechanical energy to produce electricity in a ________ ________ plant.
|
COMBINED CYCLE
|
|
|
___________ ___________Sell steam to local industrial plants and surplus electric to local utilities
|
COGENERATION PLANTS
|
|
|
Superheated steam is injected into a gas turbine to increase electrical output in the ______ _____________.
|
CHENG CYCLE
|
|
|
Waste products from sugar cane are used in a BAGASSE plant. When dried it has a heating value of ________ to _________ btus per lb
|
8000 to 8700 btus per lb
|
|
|
Black Liquor boilers are known for
|
STEAM GENERATION and production of SODA ASH
|
|
|
For black liquor boilers to sustain combustion
|
they must contain _______% solids.
|
|
|
Three types of ATMOSPHRIC BED BOILERS
|
1.) BUBBLING 2.) DEEP 3.) CIRCULATING FLUIDIZED BED
|
|
|
Minimum and Maximum size of a blowdown are
|
3/4"min - 2 1/2"max
|
|
|
Ratio of heat output to heat imput
|
BOILER EFFICIENCY
|
|
|
Pressure relief valve on a hot water boiler must be at least ___" diameter and no more than _____" in diameter
|
3/4" - 4 1/2"
|
|
|
Two types of headers in early watertube boilers
|
SINUOUS or BOX
|
|
|
Volume of a cylinder
|
V = (D X D X .7854) X H
|
|
|
Boiler Horse Power formula.
|
Lbs per hr X factor of evaporation divided by 34.5
|
|
|
Water Column Formula
|
Water coumn = P/.433
|
|
|
WATER AT ITS BOILING POINT IS CONSIDERED __________ LIQUID
|
SATURATED
|
|
|
SATURATED STEAM CONTAINS NO _______AND IS NOT _______.
|
LIQUID - SUPERHEATED
|
|
|
THE TEMP OF A LIQUID MINUS 32
|
ENTHALPY
|
|
|
CRITERIA FOR A MINIATURE BOILER
|
a) 16" DIAMETER b) 5 FT CUBED GROSS VOLUME c) 100psig OR LESS d) 20 SQUARE FEET OF HEATING SURFACE
|
|
|
UNLIKE A WATER HEATING BOILER A HOT WATER SUPPLY BOILER DOES NOT GET ______ ________.
|
RETURN WATER
|
|
|
SUPERCRITICAL BOILER OPERATES AT 3206 psia OR 705 DEGREES IN A SUPERCRITICAL BOILER WATER AND STEAM HAVE THE SAME __________.
|
Density
|
|
|
The _______ __________ turns the burner off when the steam pressure in the boiler is sufficiently low.
|
operating control
|
|
|
The maximum voltage on a control circuit is
|
150 Volts
|
|
|
Flues are specified by their _________ diameter.......Tubes are specified by their _________diameter
|
inside; outside
|
|
|
Sum of latent and sensible heat gives you what
|
Total Heat
|
|
|
Stress imposed on a boiler by a sudden drastic change in temp.
|
Thermal Shock
|
|
|
Guage pressure + atmospheric pressure
|
Absolute pressure
|
|
|
Tubes exposed to the highest temps in the furnace and contain rising water are?
|
riser tubes
|
|
|
_____________tubes contain cooler desending water replenish water to riser tubes
|
Downcomber
|
|
|
Manholes are __________in shape
|
ELIPTICAL
|
|
|
Handholes are generally __" by ___"
|
4"x5"
|
|
|
2 methods of supporting an HRT
|
1.) lug and roller 2.) overhead suspension
|
|
|
Advantages of Watertube boilers
|
1. higher capacity 2. drum not exposed to the radient heat of the fire.
|
|
|
??????____ cubic inches in 1 gallon
|
231
|
|
|
A _______ _______ is constructed of flat plates reffered to as a tubesheet and a tubecap sheet.
|
BOX HEADER
|
|
|
Bent tubes are more________ than straight tubes. Bent tubes allow for free expansion and contraction.
|
flexible
|
|
|
____________prevents the tube ends from being overheated
|
Beading
|
|
|
When a furnace baffle breaks the gasses short circuit causing excessive ______________.
|
fluegas temps
|
|
|
Welding flat strips of metal between the waterwall tubes is known as _________ ____________ construction.
|
membrane wall
|
|
|
The amount of pressure below the setpoint that must be relieved before a safety valve closes
|
BLOWBACK
|
|
|
________ are used instead of elbows on water column piping to allow for internal inspection.
|
Crosses
|
|
|
When using a lift lever to manually test a safety valve
|
the boiler pressure must be ____% of the safety valve set point
|
|
|
Under what code are oil fired boilers & their control systems covered?
|
Listed & labeled in accordance with UL 726.NFPA 8501; 8502; 8504
|
|
|
Hydrostatic test is done at what pressure?
|
150 times the MAWP or 50% over MAWP
|
|
|
What are 3 low water cutouts?
|
(Float magnet type- it has a plunger on a float rod an a permanent magnet with a mercury switch) (Float-linkage type- a linkage connected to a mercury switch) (Submerged-electrode type- uses an electrode make the complete burner circuit)
|
|
|
Blowdown shall not be less than __ or lower than __ of the safety valve?
|
Less than 2 lbs or lower than 96% of the safety valve.
|
|
|
What are 3 types of feedwater regulators:
|
Thermostatic-mechanical regulator; Thermostatic-fluid type; Float operated style
|
|
|
On a piston type trap what would cause it to open?
|
Cold Condensate Answers on test was steam psi drop and temp drop
|
|
|
If you open or close a steam stop valve to quick it will cause what?
|
Water Hammer
|
|
|
What are two types of commonly used feed water pumps
|
Injectors and Inspirator
|
|
|
What is blistering caused by?
|
A Slag Inclusion forming a lamination at time the plate was rolled in the steel mill and it is actually a separation of the metal from the shell plate; caused by impurities rolled into the shell plate when formed
|
|
|
Grooving is a form of deterioration of boiler plate by a combination of ________ and ______________.
|
localized corrosion ; stress concentration
|
|
|
What compound is not a heat producer?
|
Nitrogen
|
|
|
How many types of flame detectors are there?
|
6 Types
|
|
|
On a package boiler; how many ways could cause fire puffs when it is starting up?
|
6 ways
|
|
|
Air is _____% oxygen by weight & ______% by volume.
|
Air is 23% oxygen by weight & 21% by volume.
|
|
|
The hardgrove index is a measurement of___________.
|
Grindability
|
|
|
How many pounds of oxygen are required to properly burn 1 pound of methane?
|
4 lbs of oxygen
|
|
|
How much excess air is required to burn coal?
|
50%
|
|
|
How much air is required to correctly atomize #4 fuel oil and lighter fuel?
|
20 psi for #4 and lighter fuel 10 psi
|
|
|
A _____________ test is used to determine smoke density.
|
Ringlemann
|
|
|
A ______________ measures the difference in: pressure between two points and measures draft.
|
Manometer
|
|
|
A control that operates from steam pressure is of what type?
|
ON/OFF control
|
|
|
The flow thru a cooling tower is.
|
Horizontal to vertical and Horizontal to Horizontal
|
|
|
What does Proximate analysis of coal report?
|
1 % of moisture
|
|
|
On a HRT boilers flame impingement will cause what?
|
Hot spots/caused by refractory missing and local scale formation
|
|
|
Ultimate analysis of coal gives the % of the?
|
Various elements
|
|
|
When working on a boiler lamps less than _ should be used.
|
32 volts
|
|
|
Low pressure burners are at atmospheric an at___ and _____?
|
1 to 2 psi
|
|
|
How long can the pilot be long before the main flame is turned on.
|
15 seconds
|
|
|
At what PSI do you hold a nitrogen blanket at?
|
5 psi
|
|
|
The most common cause of furnace explosions are from.
|
Momentary failure of ignition during regular operation.
|
|
|
Five major Nondestructive tests are:
|
Ultrasonic; Radiography; Magnetic- particle; Dye-penetrant and eddy-current.
|
|
|
This is a result of putting a cooling tower to close to a building's air intake for outside air.
|
Legionaries Disease
|
|
|
Which would be the appropriate test for porosity of metal for a boiler?
|
Pulse Echo
|
|
|
Which chemical is used to combat scale ?
|
Combined phosphate treatment (Tri-Sodium phosphate)
|
|
|
Other than sulfite; what chemical is used to combat corrosion in a boiler?
|
Hydrazine
|
|
|
What is the major problem with pre-sealed gaskets?
|
Corrosion
|
|
|
How is hardness expressed ?
|
PPM of Calcium Carbonate
|
|
|
What chemicals are used to combat corrosion?
|
Sodium sulfite and Hydrazine and Catalyzed Hydrazine
|
|
|
What level of de-ionized water alkalinity is permitted for a 600 PSI boiler?
|
250 PPM
|
|
|
If there were oxygen in the system what would it cause?
|
Corrosion due to Pitting & Catalyst
|
|
|
OIL in a system will cause of following problems.
|
Foaming; Overheating and Blistering the of the tubes
|
|
|
Hide out in a boiler causes what to precipitate?
|
Sodium Phosphate
|
|
|
What is the main cause of generating tubes to failing?
|
Overheating at the lower tubes due to scale; sludge and poor circulation.
|
|
|
A boiler water having high Alkalinity could develop
|
Caustic Embrittlement
|
|
|
What does condensate polishing used for?
|
To clean & purify returned condensate
|
|
|
Acid cleaning removes what?
|
Metallic Oxide
|
|
|
Chelants controls what in a boiler systems?
|
Metal Oxide Deposits
|
|
|
To prevent condensate corrosion in the return lines you should add what?
|
Amine Morpholine & Cyclohexylamine
|
|
|
What do you do when Laying a boiler up wet?
|
If there is no deaerated water heater you should heat the water up for 8 hours with the vent open and add Sulfite & caustic soda.
|
|
|
When doing a Dry Lay up what do you put in it
|
Quick lime & Silica gel
|
|
|
This is a not a Fluorocarbon?
|
Ammonia
|
|
|
What refrigerant is flammable & Non Toxic?
|
Propane
|
|
|
Recycled & filtered refrigerant can be used where?
|
Same type & Same Owner
|
|
|
What Refrigerant Classification is Ammonia R-717?
|
B2
|
|
|
How is moisture taken out of refrigerant system?
|
Filter Drier ; high vaccum
|
|
|
What is the max toxicity level of class B refrigerant?
|
400ppm
|
|
|
On Gas fired Boilers what isthe proper Gas to Air mixture?
|
30% to 70% and can be 100% in special arrangements
|
|
|
What is the Equalizing system?
|
Equalizing system is for warming up steam lead
|
|
|
Which is not an organic sludge conditioner?
|
Amines
|
|
|
Which byproduct has the highest heating valve?
|
Butane
|
|
|
An increase of 10 to 20 degrees above design temp can reduce creep life by how many years?
|
10 to 20 (pg578-579)
|
|
|
What is ultrasound testing?
|
A nondestructive test for metal thickness in boilers. (pg 243; 610)
|
|
|
What are the causes of gas turbine blade failure?
|
Deposit accumulation; erosion; corrosion
|
|
|
What is the speed of steam through a pipe?
|
10 000 ft/sec at pressures above 16 psi 5 000 ft/sec at pressures below 16 psi
|
|
|
On an open air evaporator what is the most likely to occur?
|
Bacteria and algae build up
|
|
|
What pressure controls are on a steam boiler?
|
Operator pressure cut out and upper limit control
|
|
|
What are the temperature controls on a hot water boiler?
|
Operating limit control and upper limit control
|
|
|
On a single boiler high pressure boiler what type of valves are needed
|
Single supply OS& Y
|
|
|
What is the last device to prevent boiler from overheating
|
Flame guard system
|
|
|
Carbon dioxide is what type of refrigerant?
|
B2
|
|
|
Hot water boilers have how many manual resets on LWCO.
|
1
|
|
|
Steam boilers have how many manual resets on LWCO
|
2
|
|
|
Class 3 is how flammable?
|
Hazards
|
|
|
Hardness formula
|
(Calcium X 2.5)+ (Magnesium X 4.1)
|
|
|
Lack of penetration in a weld joint is most accuratley detected by the use of__________________ testing.
|
Radiographic - X-ray
|
|
|
The test most commonly used to determine the wall thickness of pipe and flat plate is________.
|
Ultrasonic
|
|
|
Firetube boilers are likely to leak due to cracking; burning and corrosion of the _________ _______.
|
tube ends
|
|
|
The ratio of a boiler's heat output to it's heat input is_____________________.
|
boiler efficinncy
|
|
|
Welding flat strips of metal between the waterwall tubes is known as ________ wall construction.
|
membrane
|
|
|
The general classification of superheaters includes _________ and _________ types.
|
Radient and Convection
|
|
|
Pipes connecting the water column to the boiler must be a minimum diameter of _____"
|
1"
|
|
|
Cogeneration plants sell ____ to local industrial plants and______ to the local utility.
|
Steam ; Electricity
|
|
|
Saftey Valve capacity must be sufficient to relieve all the steam that the boiler can generate at the _____ _____ ______ without allowing the pressure to rise more than _% above the MAWP.
|
Max firing rate ; 6%
|
|
|
The______ _______ mechanism on the High Limit Control calls attention if the _________ control has malfunctioned.
|
Manual reset ; Operating control
|
|
|
A slow opening blowdown valve must complete _______ turns between full open and full shut.
|
5
|
|
|
Perminatly hard water is water that contains large quantities of calcium and magnesium ________
|
Sulfates
|
|
|
_________ is used on high pressure steam plants to absorb oxygen. It is not typically used on low pressure plants because it is a slow reaction to absorb oxygen.
|
Hydrazine
|
|
|
________ usually causes cavities to form at grain boundaries and these cavities coalesce to form a crack.
|
CREEP
|
|
|
Leaking saftey valves should be _____________ to stop leakage never tightened by adjustment.
|
regrounded
|
|
|
The temperature of a liquid minus 32 is its_________.
|
enthalpy
|
|
|
Film boiling inside the boiler tubes can cause above normal tube metal temperatures and can be the result of __________ ____________________________.
|
poor circulation
|
|
|
Butane and propane are produced from the manufature of gasoline. Propane has a heating value of _______btu's per cubic foot; butane has a heating value of__________btu's per cubic foot.
|
Butane=3200 Propane=2500
|
|
|
The maximum adjustment to the setpoint of a saftey valve is ____%
|
10%
|
|
|
Rectifying phototube and cadmium sulfide phototube both prove flame in the boiler by sensing_________ _________.
|
visible light
|
|
|
________ _______ boilers recover exaust from a gas turbine to produce usful steam.
|
waste heat
|
|
|
An open type expansion tank shall be located at least ___ feet above the highest heating element.
|
4
|
|
|
One grain =______ppm. _____________ grains equals one lb
|
17.1
|
|
|
Oil fired burners and their components should be listed and labled in accordance with _________.
|
UL 726
|
|
|
Electric boilers and their control systems shall be listed and labled in accordance to _______.
|
UL 834
|
|
|
The ratio of the maximum fuel input rate and the minimum fuel input rate is known as the______________ __________.
|
turndown ratio
|
|
|
A condition that occurs when steam bubbles are generated so quickly from a boiler heating surface that a layer of steam is formed between the water and the heating surface.
|
steam blanketing
|
|
|
An extremely large boiler that generates steam at a very high pressure and temperature
|
utility watertube boiler
|
|
|
a boiler with a seperate furnace area that is usually built of refractory brick
|
externally fired firetube boiler
|
|
|
A rotating machine used to generate electricity from the flow of hot gases of combustion
|
gas turbine
|
|
|
The heat added to the water in an actual boiler in btu/lb and divided by 970.3
|
factor of evaporation
|
|
|
What is the recommended time for complete external inspection of a boiler?
|
Once a shift
|
|
|
In a 24hr operation; how often should you check the boiler water level?
|
Once a shift
|
|
|
How often is it recommended to check the low water cut off (LWCO)?
|
Once a shift
|
|
|
How often should you check the high limit switch?
|
Annually
|
|
|
How often should the testing and inspecting of boiler components be done?
|
Semi annually
|
|
|
How often should you test an operating control?
|
Annually
|
|
|
How often should you test water columns and water glass level be checked on a high Pressure boiler?
|
At the beginning of every shift/ beginning of work efforts
|
|
|
How often do you test your float controls on a high-pressure boiler?
|
Every shift
|
|
|
How often do you test your float controls on a hot water boiler?
|
Weekly
|
|
|
How often do you test a safety valve with pressure?
|
Annually
|
|
|
How often do you test a safety valve with a lever test?
|
Monthly
|
|
|
What controls blowback on a safety valve?
|
The blowback ring or adjusting ring
|
|
|
What is the most important safety device on a boiler?
|
Relief valve
|
|
|
What are the min and max size of a safely valve per code for boilers?
|
Min 1/2 and max 4 1/2
|
|
|
What stamp is put on a safety valve after it has been repair?
|
VR stamp
|
|
|
How do you protect a pressure vessel?
|
Pressure relief valve
|
|
|
How do you protect a hot water boiler?
|
Pressure relief valve
|
|
|
This part of the safety valve works in conjunction with the adjusting ring to allow it to pop open?
|
Huddling Chamber
|
|
|
What do you do if a safety valve is leaking?
|
Reground seat
|
|
|
A safety valve discharge pipe should go how high when workers maybe present?
|
6 feet high
|
|
|
If 2 safety valves are used with the same discharge pipe the discharge line must have?
|
The same area as both valves area
|
|
|
Every discharge valve should have a?
|
3/8 to 1/2 drain
|
|
|
What are the Blowback setting on a safety valve?
|
Up to 4% but not less than 2 lbs
|
|
|
Safety relief valves are repaired to what rules.
|
NB rules.
|
|
|
Safety valve Name plate has;
|
Manufacturer's name or trade mark/ type or design#/ Size/ seat dial/ set pressure/blowdown/ Discharge capacity lb per hr/ capacity lift/ AMSE symbol or NB stamping.
|
|
|
What percentage of boiler pressure is needed to hand check a boiler safety valve?
|
75%
|
|
|
On an open air expansion tank; hot boiler system; how high should it be mounted?
|
4 feet above the highest heating element.
|
|
|
What are man holes & hand holes on a boiler for?
|
Inspections and cleaning
|
|
|
Under what code are fuel boilers designed & constructed?
|
ASME-CSD 1
|
|
|
What is the legal limit of acceptable asbestos particles?
|
Permissible exposure limit per OSHA regulations for an 8 hr day is?
|
|
|
What is a confined space minimum oxygen level for entry?
|
19%
|
|
|
What is the minimum clearance needed when a capacity of 5000lbs/hr or heating surface Over 1000 sq ft or an input over 5 000 000 Btu's/hr
|
7 ft
|
|
|
Under all the above limits what would be the minimum clearance?
|
3 ft
|
|
|
What is the minimum clearance of boilers without manhole covers on top?
|
2 ft
|
|
|
Under what code are oil fired boilers & their control systems covered?
|
Listed & labeled in accordance with UL 726.NFPA 8501
|
|
|
Data printed on a piece of equipment name plate would include manufacturer.
|
model #;
|
|
|
How high is a pull station mounted on a wall?
|
48 inches
|
|
|
When working in a boiler work permits should be acquired?
|
For the work shift
|
|
|
To inspect a boiler they must be what?
|
Be employed either by the state or by an insurance company licensed to write boiler and pressure vessel insurance in that jurisdiction
|
|
|
A boiler should have 1 spring loaded pop-type safety valve and it must exceed the output lb's per hour & fuel capacity but not raise above
|
5 psi of the MAWP or 6%.
|
|
|
ASME CSD 1 requires the main gas burners train to have what?
|
2 manual safety shutoff valves
|
|
|
Welds must be approved and witnessed who?
|
Authorized inspector
|
|
|
Hydrostatic test is done at what pressure?
|
150 times the MAWP or 50% over MAWP
|
|
|
During a hydro test if the boiler leaks who do you notify?
|
Authorized boiler inspector and they will advise you what to do.
|
|
|
How many low water cut offs are needed per code for hot water boiler systems?
|
When the boiler has an input greater than 400 000 BTU's per hr 1 L.W. cutout is needed
|
|
|
What are the minimum and maximum sizes permitted for blowdown valves or connection?
|
(3/4 min & 2 1/2 max)
|
|
|
What are the gauges on a hot water boiler?
|
Pressure gauge & temperature gauge.
|
|
|
What are the gauges on a steam boiler?
|
Pressure gauge and gauge glass
|
|
|
A boiler operating at a pressure of 65 lbs; what is the smallest size feed & blow off connections if the safety valve is set at 90 psi?
|
1/2 feed & 3/4 blow off
|
|
|
If a boiler has 1" blow down pipe; what diameter should the boiler blow down tank air vent should be?
|
2.5"
|
|
|
What are 3 low water cutouts?
|
Float magnet type- it has a plunger on a float rod an a permanent magnet with a mercury switch; Float-linkage type- a linkage connected to a mercury switch; Submerged-electrode type- uses an electrode make the complete burner circuit
|
|
|
What does a low water cut out do in a low water condition?
|
Shuts off the fuel supply when it drops below the visible level
|
|
|
What is the first indication of low water condition?
|
A red hot crown sheet
|
|
|
How many low water cutouts are needed for steam & hot water boilers?
|
ONE
|
|
|
Boiler that exceeds 100 psi must have how many blow downs?
|
TWO
|
|
|
How many times the safety valve setting should the pressure gauge be?
|
(1 1/2 to 2 times)
|
|
|
When blowing down the water column you notice the gauge glass slowly returns to the normal level; this could be indication of what?
|
The bottom of the gauge glass is clogged and giving a false reading
|
|
|
How many inches should the lowest visible level in the gauge glass be in a boiler?
|
TWO inches
|
|
|
What are the minimum gauge glass connection and drain?
|
(1/2 connection and 1/4 drain)
|
|
|
Blowdown shall not be less than ** or lower than ** of the safety valve?
|
Less than 2 lbs or lower than 96% of the safety valve.
|
|
|
Blow down valves fitting should be designed at least ** % greater pressure than the MAP?
|
25%
|
|
|
In an old power boiler which type of feed water regulator wouldn't be used?
|
Electronic
|
|
|
Which low water cut out doesn't have a mercury switch?
|
Electrode probes (submerged)
|
|
|
What are 3 types of feedwater regulators?
|
Thermostatic-mechanical regulator; Thermostatic-fluid type; Float operated style
|
|
|
What are two types of commonly used feed water pumps?
|
Injectors and Inspirator
|
|
|
What is a piping arrangement used to return condensate from steam lines separators to the boiler?
|
Holly Loop
|
|
|
What would happen if high temperature liquid passes though a centrifugal pump?
|
Wire Drawing
|
|
|
Multistage pumps can be of what type?
|
Volute or Diffuser type
|
|
|
To prevent cavitations most pump are stamped with a?
|
Net Positive Suction Head
|
|
|
What two types are of condense return systems.
|
Mechanical return systems - use traps and pumps to aid in condensate return; Gravity return systems - use gravity to bring condensate back
|
|
|
To prevent super heater from overheating on start up what should you do?
|
Either flood the tubes with Water or the super heater should be vented to the atmosphere by a free blow valve until the boiler goes online.
|
|
|
This device acts as a check valve in both directions and keeps the pump primed?
|
Foot valves are used for pumps under suction pressure to prevent back flow on the suction line.
|
|
|
How does steam flow through pipes?
|
Larger diameter slower the flow; smaller diameter higher velocity; Pressure difference draws flow
|
|
|
This pump has a water piston directly connected to a steam driven piston via rod.
|
Reciprocating
|
|
|
A boiler system has a single boiler supplying 160 psi steam; what valves are necessary?
|
an OS&Y shutoff valves are required on both supply and return.
|
|
|
On a piston type trap what would cause it to open?
|
Cold Condensate (Answers on test was steam psi drop and temp drop)
|
|
|
If you open or close a steam stop valve to quick it will cause what?
|
Water Hammer
|
|
|
When testing a low water fuel cutoff using an evaporation test you need to secure all the; what going to the boiler?
|
Feed water
|
|
|
When 2 boilers are on the same common steam main there must be 2 OS&Y valves
|
The 1st valve being an Automatic Non-return valve and an ample free blowing drain between them
|
|
|
An Automatic Nonreturn valve prevents backflow if one boiler goes down and is found on.
|
The main steam line between the boiler and the steam stop valve
|
|
|
What is put on a boiler after repairs?
|
R Stamp
|
|
|
What is the first thing you do when shutting down a boiler?
|
Turn off the fire or Extinguish fire.
|
|
|
What is creep?
|
Creep is defined as slow deformation of metal with time; with the deformation taking place at elevated temperatures with no increased stress (a small hairline crack)
|
|
|
What is bulging?
|
Bulging is caused by overheating of shell plates & it affects the entire thickness of the plate it due to scale; oil; mud; or a localized flame on the shell.
|
|
|
What mechanical device removes scale from a firetube boiler?
|
Vibrator and a Tube Rattler.
|
|
|
What mechanical device removes scale from a watertube boiler?
|
Tube Turbine
|
|
|
What is blistering caused by?
|
A Slag Inclusion forming a lamination at time the plate was rolled in the steel mill and it is actually a separation of the metal from the shell plate; caused by impurities rolled into the shell plate when formed
|
|
|
Say bolt universal is a measurement of what?
|
Viscosity
|
|
|
Stay bolt failure is usually caused by.
|
xpansion & contraction and FATIGUE
|
|
|
Creep gets worst with what?
|
Elevated temperature
|
|
|
What type of valve would not be good choice if sediment were present?
|
Globe valve
|
|
|
How many BTU does it take to take 10 lbs of steam from 40 to 41 degrees?
|
10 BTU
|
|
|
What is it called when you leave a piece of equipment fail before you replace it?
|
Breakdown maintenance
|
|
|
What % of blistering or bulging is ok?
|
2%
|
|
|
What boiler are stay bolts found in?
|
Fire tube boilers
|
|
|
1 boiler hp is equivalent to the evaporation of _____ pounds of steam an hour.
|
34.5 lbs
|
|
|
8 foot length of tube or shell can take up to_% sag or bend and still be used without replacing .
|
2%
|
|
|
Circulating tubes are connected to the __ space to the steam drums to aid in equalization of the boiler water.
|
Water
|
|
|
Grooving is a form of deterioration of boiler plate by a combination of?
|
Localized corrosion and stress concentration
|
|
|
The minimum and max of ferrous and nonferrous pipe is?
|
1 min and 3 max
|
|
|
Equalizing tubes are connected to the steam space of such drums to equalize the _ pressure.
|
Steam
|
|
|
What is the substance that transfers electrical current in a photo cell?
|
Cadmium will transfer current when exposed to light
|
|
|
What substance is used for electric transmission in RDT (resistance temperature detector)?
|
Platinum because of its stability at high temperatures
|
|
|
What protects the boiler from explosion in the furnace?
|
Flame guard systems
|
|
|
A device used to measure flue gases.
|
Orsat Analyzer which measures CO CO2 & nitrogen
|
|
|
How much excess air is needed for combustion of pulverized coal; gas; oil?
|
10 to 30%
|
|
|
What is the BTU rating of Anthracite?
|
14000 Btu’s/lb
|
|
|
What is the BTU rating of # 4 fuel oil?
|
18 840 Btu’s/lb
|
|
|
What compound is not a heat producer?
|
Nitrogen
|
|
|
What takes no actual action in combustion?
|
Nitrogen
|
|
|
How many things do safety controls guard against?
|
Overpressure; leading to explosion from the water or steam side of the system; Overheating of metal parts
|
|
|
How many types of flame detectors are there?
|
6Types 1 Stack switch - which senses heat. 2 Rectifying flame rod - which senses heat. 3 Rectifying photo cell tube visible- which is light sensitive. 4 Lead sulfide photo cell- which senses infrared light. 5 Cadmium Sulfide photo cell visible- which senses light. 6 Ultraviolet flame detector tube- which senses ultraviolet light.
|
|
|
On a package boiler
|
how many ways could cause fire puffs when it is starting up?
|
|
|
What is the grade of light domestic fuel oil?
|
#1
|
|
|
A lead sulfide photocell senses what type of light?
|
Infrared light sensing
|
|
|
What is the % of content air by weight and by volume?
|
Air is 23% oxygen by weight & 21% by volume.
|
|
|
The hardgrove index is a measurement of.
|
Grindability
|
|
|
How many pounds of oxygen are required to properly burn 1 pound of methane?
|
4 lbs of oxygen
|
|
|
What is a black liquor boiler used for?
|
Is a bi-product of wood pulp processing in the paper making industry makes steam and soda ash
|
|
|
A black liquor boiler requires what percentage of solids of fuel to maintain proper combustion?
|
58%
|
|
|
This flame monitor can easily get a false reading from hot refractory walls?
|
Rectifying Photo Tube
|
|
|
How much air is required to correctly atomize #4 fuel oil and lighter fuel?
|
20 psi for #4 and lighter fuel 10 psi
|
|
|
How much excess air is required to burn coal?
|
50%
|
|
|
Which coal has the lowest heating value?
|
Lignite
|
|
|
After a section of boiler plate loses_ of its metal; it will have to be cut out & a new patch welded in place?
|
50%
|
|
|
What does proximate analysis of coal report?
|
1 % of moisture; 2 Volatile matter; 3 fixed carbon and ash content.
|
|
|
What is Fretting?
|
Is 2 metals rubbing together each other destroying the protective film exposing their surface to new oxidation.
|
|
|
A Ringlemann test is used to determine what?
|
Smoke density.
|
|
|
Manometer measures the difference.
|
Pressure between two points and measures draft.
|
|
|
A control that operates from steam pressure is of what type?
|
ON/OFF control
|
|
|
On a HRT boilers flame impingement will cause what?
|
Hot spots; caused by refractory missing and local scale formation
|
|
|
Ultimate analysis of coal gives the % of the?
|
Various elements
|
|
|
When working on a boiler lamps less than _ should be used.
|
32 volts
|
|
|
Low pressure burners are at atmospheric an at _ and __?
|
1 to 2 psi
|
|
|
How long can the pilot be long before the main flame is turned on?
|
15 seconds
|
|
|
At what PSI do you hold a nitrogen blanket at?
|
5 psi
|
|
|
The most common cause of furnace explosions are from.
|
Momentary failure of ignition during regular operation.
|
|
|
Five major Nondestructive tests are:
|
Ultrasonic; Radiography; Magnetic- particle; Dye-penetrant and eddy-current.
|
|
|
The flow thru a cooling tower is.
|
Horizontal to vertical and Horizontal to Horizontal
|
|
|
This is a result of putting a cooling tower to close to a building's air intake for outside air.
|
Legionaries Disease
|
|
|
This burner can burn almost any fuel oil at any temperature & at any viscosity.
|
Steam atomizing burner
|
|
|
Which would be the appropriate test for porosity of metal for a boiler?
|
Pulse echo
|
|
|
With normal oxygen and low alkalinity
|
what is added to the boiler water?
|
|
|
What is hard forming scale?
|
Silica
|
|
|
Which chemical is used to combat scale?
|
Combined phosphate treatment (Tri-Sodium phosphate)
|
|
|
Other than sulfite; what chemical is used to combat corrosion in a boiler?
|
Hydrazine
|
|
|
What will neutralize acids?
|
Alkali; Lime soda and soda ash
|
|
|
Where is internal corrosion most likely to occur in a Vertical boiler?
|
At the Water legs near the Bottom ring or ogee flange ;Mud legs; Mud rings.
|
|
|
What is the major problem with pre-sealed gaskets?
|
Corrosion
|
|
|
How is hardness expressed in?
|
PPM of Calcium Carbonate
|
|
|
With hydroxide present & normal oxygen levels; which chemical will cause problems?
|
Chlorine
|
|
|
What chemicals are used to combat corrosion?
|
Sodium sulfite and Hydrazine and Catalyzed Hydrazine
|
|
|
If you have your boiler water has a PH of 5. What compound type do you add to neutralize it?
|
Bases which reacts with the acids to form salt
|
|
|
In a vertical boiler where is the first place to check for thinning of the tubes?
|
Water legs especially at the bottom or on the combustion side at the upper ends of the tubes.
|
|
|
What produces soft scale?
|
Calcium & Magnesium Carbonate and Magnesium Chorine
|
|
|
What level of de-ionized water alkalinity is permitted for a 600 PSI boiler?
|
250 PPM
|
|
|
If there were oxygen in the system what would it cause?
|
Corrosion due to Pitting & Catalyst
|
|
|
OIL in a system will cause of following problems.
|
Foaming Overheating and Blistering the of the tubes
|
|
|
Hide out in a boiler causes what to precipitate?
|
Sodium Phosphate
|
|
|
What is the main cause of generating tubes to failing?
|
Overheating at the lower tubes due to scale sludge and poor circulation.
|
|
|
A boiler water having high Alkalinity could develop.
|
Caustic Embrittlement
|
|
|
What does condensate polishing used for?
|
To clean & purify returned condensate.
|
|
|
Acid cleaning removes what?
|
Metallic Oxide
|
|
|
Chelants controls what in boiler systems?
|
Metal Oxide Deposits
|
|
|
To prevent condensate corrosion in the return lines you should add what?
|
Amine Morpholine & Cyclohexylamine
|
|
|
What do you do when laying a boiler up wet?
|
If there is no deaerated water heater you should heat the water up for 8 hours with the vent open and add Sulfite & caustic soda.
|
|
|
When doing a Dry Lay up what do you put in it?
|
Quick lime & Silica gel
|
|
|
This is a not a Fluorocarbon?
|
Ammonia
|
|
|
What refrigerant is flammable & Non Toxic?
|
Propane
|
|
|
Recycled & filtered refrigerant can be used where?
|
Same type & Same Owner
|
|
|
What Refrigerant Classification is Ammonia R-717?
|
B2
|
|
|
In Refrigeration system
|
the purpose of condenser is.
|
|
|
What is oil in Refrigerant for?
|
Lubricating and cooling compressor
|
|
|
How is moisture taken out of refrigerant system?
|
Filter Drier high vacuum
|
|
|
What type of gas don't you used to test an AC system?
|
Oxygen
|
|
|
What is the maximum line to line voltage for a boiler control circuit?
|
150 volts
|
|
|
A fuel oil that has an API of 32 has how many Btu’s lbs of heating?
|
19 490 BTU's
|
|
|
Which fuel oil has to be heated prior to use?
|
4;5;6
|
|
|
What is the max toxicity level of class B refrigerant?
|
400 ppm
|
|
|
Name 5 possible steps in water treatment.
|
1 Pre-treatment of raw water supply; 2 Treatment of the make up water going to the boiler; 3 Internal treatment of the water on the boiler; 4 Treatment of condenser water being returned to the boiler; 5 Blow down controls to remove precipitated sludge from the boiler.
|
|
|
On Gas fired Boilers the proper Gas to Air mixture is what?
|
30% to 70% and can be 100% in special arrangements.
|
|
|
What size pipe is used as a header in a boiler operating at 100 psi?
|
6 inches
|
|
|
What is Domestic fuel oil?
|
2
|
|
|
What function can operator contribute to boiler maintenance?
|
1 Maintain safe plant; 2 maintain an efficient plant; 3 Inspect & Log items that need to be corrected.
|
|
|
What is the Equalizing system?
|
Equalizing system is for warming up steam lead.
|
|
|
What are the feed water stop and valves used for?
|
To manually feed the boiler
|
|
|
A steam pump with two pistons?
|
Duplex Direct acting steam pump
|
|
|
How many water cut outs are needed for steam boilers?
|
2
|
|
|
Boilers use what to transfer heat?
|
Convection; radiation; and conduction
|
|
|
Which is not an organic sludge conditioner?
|
Amines
|
|
|
Which byproduct has the highest heating valve?
|
Butane
|
|
|
An increase of 10 to 20 degrees above design temp can reduce creep life by how many years?
|
10 to 20 (pg578-579)
|
|
|
Which coal burns with a yellow smoky flame?
|
Bituminous
|
|
|
What is ultrasound testing?
|
A nondestructive test for metal thickness in boilers. (pg 243 - 610)
|
|
|
What are the causes of gas turbine blade failure?
|
Deposit accumulation; erosion; corrosion
|
|
|
A high pressure boiler generates how many psi of steam?
|
15 psig
|
|
|
What is the speed of steam through a pipe?
|
10 000 ft/sec at pressures above 16 psi 5 000 ft sec at pressures below 16 psi
|
|
|
On an open air evaporator what is the most likely to occur?
|
Bacteria and algae build up.
|
|
|
What pressure controls are on a steam boiler?
|
Operator pressure cut out and upper limit control.
|
|
|
What are the temperature controls on a hot water boiler?
|
Operating limit control and upper limit control.
|
|
|
On a single boiler high pressure boiler what type of valves are needed.
|
Single supply OS& Y
|
|
|
On a 2 inch valve Auxiliary steam what valves are needed.
|
OS&Y
|
|
|
What is the last device to prevent boiler from overheating.
|
Flame guard system.
|
|
|
What is the lowest by product?
|
Blast furnace
|
|
|
Know load control and metering control.
|
SEARCH FOR THIS ONE..
|
|
|
Oil can be removed with.
|
Caustic soda and soda ash
|
|
|
Know the 10 most Generating plant tube failures?
|
Find it
|
|
|
What does an evaporator does?
|
Absorbs heat
|
|
|
Reclaimed refrigerant can be used by any one.
|
The same owner
|
|
|
Carbon dioxide is what type of refrigerant?
|
B2
|
|
|
Hot water boilers have how many manual resets.
|
1 manual reset on LWCO.
|
|
|
Steam boilers have how many manual resets.
|
2 manual resets on LWCO
|
|
|
Electric air filters take all but what out of the air?
|
Either white dust or smoke?
|
|
|
A panic Class A station is mounted how high?
|
48 inches ?
|
|
|
What is the popping tolerance of a safety valve set a 1200 psi?
|
Answer were 10LB; 12LB or 10 %
|
|
|
A safety valve should pop at what?
|
Boiler mawp on the boiler name plate
|
|
|
What makes the steam pressure change?
|
Load on Boiler and the Fuel supplied to the Burner
|
|
|
Class 3 is how flammable?
|
Hazards; explosive or high flammable
|
|
|
A reducing valve Has 125 psi on the inlet side and 30 psi on the outlet side; what is the relief valve capacity required for the low side?
|
17736 lbs/hr
|
|
|
This is the relief valve capacity equation.
|
RVC=1/3 x OC x VSPA
|
|
|
This is the Bypass valve equation.
|
RVC= 1/2 x OC x BPA
|
|
|
Meaning of valve capacity equation.
|
RVC= Relief valve capacity required; lb steam/hr OC = Orifice capacity lb steam/hr inch square BPA= Bypass pipe area inch square.
|
|
|
80 inlet and 30 out 2” pipe.
|
25 inlet 3”pipe
|
