Stationary Engineer Exam Questions and Answers for Boiler Operations, Exams of Engineering

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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? - Correct Answer- 7 feet On a gas fired boiler what is the proper gas to air mixture - Correct Answer-30%-70% and in special arrangements it can be as high as 100%. ANSWER CHAPTER 11 remember% 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? - Correct Answer- TH=(Ca x 2.5) + (Mg x 4.1)\nTH=(60 x 2.5) + (18 x 4.1)\nTH= 150+73.8 =( 223.8 PPM) How often should a complete external inspection of the boiler be done? - Correct Answer-Once a Shift With 24 hr operation how often do you check the water level?

• Correct Answer-Once per shift

How often do you check the LWCO? - Correct Answer-Once per shift How often do you check the High Limit Switch? - Correct Answer-Annually A 2" pipe was found to be delivering water at 100 psia at 1040ft per second. How many gallons per hour will it deliver? - Correct Answer-GPM= V (diameter squared) divided by. ANSWER pg 469 BOG What controls the amount of blowback on a safety valve? - Correct Answer-Blowback ring or adjusting ring On a open air expansion tank hot water boiler system; how high should it be mounted? - Correct Answer-(4 Feet ) above the highest heating element. What is the minimum top clearance of boilers with manholes?

• Correct Answer-5 feet

Package boilers; steam heating boilers and hot water heating boilers shall have a minimum clearance of? - Correct Answer- feet from ceiling. Code chapter 10 page Most important safety device on a boiler? - Correct Answer- Safety relief valve What does a Black Liquor Boiler do? - Correct Answer-Black Liquor is the by product of wood pulp processing in the paper making industry. What does Black liquor boiler known for? - Correct Answer- Steam generation and recovery of soda ash Maximum line voltage for control on a boiler? - Correct Answer-150 volts Under what code are boilers designed and constructed? - Correct Answer-ASME- CSD 1 How many low water cut offs are needed per code for a hot water system when a boiler has inputs greater than 400, btu per hr - Correct Answer-1 LWCO is needed.

What is the minimum and maximum size for a safety valve per code for boilers? - Correct Answer-Minimum 3/4" and Maximum 4 1/2" What stamp is put on a boiler after repairs? - Correct Answer-"R" What is the equalizing system used for? - Correct Answer-The equalizing system is for warming up the steam lead. A blowdown valve is located at the lowest water space of a boiler for three purposes - Correct Answer-1. to remove precipitated sludge or loose scale \n2. To permit rapid lowering of the boiler water if it has become too high accidentally \n3. 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. In the old power boiler which type of feed-water regulators were not used? - Correct Answer-Electronic

After opening a boiler for repairs how much oxygen is needed? - Correct Answer-19% What is the first thing you do when shutting down a boiler? - Correct Answer-Turn off (extinguish fire) What is the legal limit of acceptable asbestos particles? - Correct Answer-0.1 fibers per cubic centimeter What is CREEP? - Correct Answer-Creep is defined as the slow deformation of material with time; with the deformation taking place at elevated temperatures with no increase in stress. What is the BTU content of Anthracite coal? - Correct Answer- 14000 btu/lb What substance transfers electrical current in a photocell? - Correct Answer-Electricity will flow when the CADMIUM is exposed to sufficient light. What device acts as a check valve in both directions and keeps pumps primed? - Correct Answer-FOOT VALVES are used for

pumps under suction pressure to prevent backflow primed? on the suction line. What protects boilers from explosion in the furnace? - Correct Answer-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). What size pipe is used as a header in a boiler operating at 100psi? - Correct Answer-6 inches What device is used to measure flue gasses - Correct Answer- The Orsat Analyzer Which low water cut off does not have a mercury switch? - Correct Answer-The Submerged electrode type What is the btu output per lb of #4 fuel oil? - Correct Answer- 18

What substance is used for the electric transmission in an RTD? - Correct Answer-Platinum is used because of its stability at high temperatures How much air is needed for the combustion of pulverized coal; gas; oil? - Correct Answer-50% for coal and 10-30% for gas & oil In old power boilers which type of feedwater regulators were not used? \n(A) hydraulic \n(B) float \n(C) thermostatic expansion \n(D) electronic - Correct Answer-ANSWER D electronic/electro-magnetic What is hard forming scale? - Correct Answer-Silica With hydroxide present and normal oxygen levels which chemical will cause problems? - Correct Answer-Chlorine The result from steel manufacturing and under pressure in boilers tends to cause buldging? A buldge is caused by? - Correct Answer-A buldge is caused by overheating of the shell plates and it affects the entire thickness of the plate.

A blister is caused by what? - Correct Answer-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. With normal oxygen and low alkalinity. what is added to the boiler water? - Correct Answer-Neutralizing Amines Which chemical is used to combat scale? - Correct Answer- Combined phosphate treatment- sodium phosphate Other than sulfite what chemical is used to combat corrosion in boilers? - Correct Answer-Hydrazine What will neutralize acid? - Correct Answer-Alkali and Lime Soda What mechanical device is used to remove scale from firetubes? - Correct Answer-A tube rattler or vibrator What percentage of the pressure should a boiler have before you test the lever of a safety valve? - Correct Answer-75%

Where is internal corrosion most likely to occur on a vertical tube boiler? - Correct Answer-Water leg-Mud leg What are the minimum and maximum sizes permitted for blow down valves or connections? - Correct Answer- 3/4"minimum 2 ½ " maximum 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? - Correct Answer-½ " feed ¾ " blow off How often should water columns and water glass levels be checked on a high pressure boiler? - Correct Answer-(Once A Shift)\nAt the beginning of each shift - beginning of the work effort What takes no actual action chemical part in combustion? - Correct Answer-Nitrogen How many ppm of EDTA are needed to tie up 1ppm of hardness? - Correct Answer-EDTA requires 10ppm of EDTA and 5 NTA to tie up each 1ppm hardness.

On a package boiler; how many ways could cause fire puffs when it is started up? - Correct Answer-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 What is the grade of light domestic fuel oil? - Correct Answer- Grade 1 ( Number 1 ) How often should you test the operating control? - Correct Answer-Annually How often should the testing and inspecting of the burner component? - Correct Answer-Annually A lead sulfite photocell is what type of flame sensor? - Correct Answer-Infrared light sensing What is the least amount of oxygen needed when a nitrogen blanket is used? - Correct Answer-19%

How should a boiler be prepared for inspection? - Correct Answer-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. What function can a boiler operator contribute to boiler maintenance? - Correct Answer-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 What are manholes and handholes on a boiler for? - Correct Answer-Examination or cleaning

How do you protect a steam boiler? - Correct Answer-Safety valve How to you protect a pressure vessel? - Correct Answer- Pressure relief valve How do you protect a hot water boiler? - Correct Answer- Pressure relief valve What gages are on a steam boiler? - Correct Answer-Water gage glass and pressure gage Methods used to control the temperature of a superheater? - Correct Answer-Bypass damper - spray-type desuperheater - attemperator - condenser - tilting burner - flue gas recirculation What chemical would you use to prevent hard scale from forming in the boiler tubes? - Correct Answer-Disodium phosphate and trisodium phosphate

What chemical compounds in water cause permanent hardness? - Correct Answer-Calcium sulfate and magnesium sulfate What factors must be taken into consideration when choosing a control for a boiler? - Correct Answer-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 How many safety controls shut down a boiler when an unsafe condition occurs? - Correct Answer-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 In a steam generating system what is blamed on chemical treatment but is in fact part of a boiler design? - Correct Answer-Poor circulation Class A Fires??? - Correct Answer-Wood - sawdust - paper - rags

Class B Fires?? - Correct Answer-Flammable liquids - oils - tars and gasses Class C Fires?? - Correct Answer-Electrical equipment 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? - Correct Answer-7 feet Under what code are oil fired boilers and their control systems covered? - Correct Answer-O.F.B 726 A data plate has what information?? - Correct Answer- manufacturer - model serial number - stamp of approval When working in a boiler work permits should be aquired when? - Correct Answer-For Each Shift ASME code requires that a LWCO control be tested by evaporation how often?? - Correct Answer-Monthly

ASME CSD1 requires the main gas burner to have what? - Correct Answer-2 manual shutoff valves. pg 81 1004.1 code book A HYDROSTATIC test is done at what pressure? - Correct Answer-1.5 times the MAWP or 50% over MAWP How many low water cutoff are needed per code on a hot water system? - Correct Answer-One LWCO is needed when the boiler input is greater than 400 000 btus What gages are on a steam boiler? - Correct Answer-pressure gage - water gage glass What gages are on a HW boiler? - Correct Answer-pressure - Temp Name three types of low water cutoffs. - Correct Answer-1. float magnetic (rod to magnet to mercury switch) 2. Float linkage- link to mercury switch 3. Submerged electrode- water

Boilers having more than 500square feet of heating surface should have how many means of feed water? - Correct Answer- Types of FEEDWATER REGULATORS - Correct Answer- 1.Thermostatic mechanical regulator 2. Thermostatic fluid style 3. Float operated style Name two types of commonly used feedwater pumps - Correct Answer-Injector and Inspirator What piping arrangment is used to return condensate from steam lines and steam seperators? - Correct Answer- HOLLYLOOP What would happen if high temp liquid passes through a centrifugal pump? - Correct Answer-WIRE DRAWING A multi stage pump can be either __________ or_______? - Correct Answer-Volute or Diffuser

To prevent cavitation most pumps are stamped with the ____ _______ _______ ____? - Correct Answer-NET POSITIVE SUCTION HEAD What are two types of condensate return systems?? - Correct Answer-a.) Mechanical Return ; uses steam traps and pumps to aid return b.) Gravity Return System : uses gravity TO PREVENT THE SUPERHEATER FROM OVERHEATING ON START UP WHAT SHOULD YOU DO - Correct Answer-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. What device acts as a check valve in both directions and keeps the pump primmed? - Correct Answer-FOOT VALVES ARE USED ON PUMPS UNDER SUCTION PRESSURE AND PREVENT FLOW ON SUCTION LINE WHAT PUMP HAS A WATER PISTON DIRECTLY CONNECTED TO A STEAM DRIVEN PISTON VIA A ROD? - Correct Answer- RECIPRICATING

What causes a piston type trap to open? - Correct Answer-cold condensate (on test the steam psi drop and temp drop was used) Quickly opening a steam valve will cause _______ ________. - Correct Answer-water hammer What mechanical device removes scale from a watertube boiler? - Correct Answer-a tube turbine What causes blistering? - Correct Answer-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. To internally remove oxygen from the boiler use______ ________. - Correct Answer-Sodium Sulfite A positioning control system is used on a ______ ________ - Correct Answer-a process boiler

A saybolt universal is a - Correct Answer-measurement of viscosity Creep gets worse with _______________ __________ - Correct Answer-elevated temps What type of valve WOULD NOT be a good choice if sediment were present - Correct Answer-GLOBE How many btus does it take to take 10 lbs of steam from 40 to 41 degrees - Correct Answer-10 btus 1btu=1lb What is it called when you let a peice of equipment fail before you repair/replace it? - Correct Answer-Breakdown maintenance What percent of blistering or buldging is ok? - Correct Answer- 2% What kind of boiler are staybolts found on? - Correct Answer- Fire tube boilers

A 8 foot length of tube or shell can take up to ___% sag or bend and still be used without replacing? - Correct Answer-2% What does a low water cutoff do in a low water condition? - Correct Answer-Shuts off fuel supply What is the first indication of a low water condition - Correct Answer-A red hot crown sheet If a boiler exceeds 100psi it must have how many blowdowns?

• Correct Answer- What is the appropriate test for checking porosity of the metal? - Correct Answer-PULSE ECHO ( A TYPE OF ULTRASONIC) What chemicals are used to combat corrosion? - Correct Answer-Sodium Sulfite; hydrazine; catalied hydrazine If your boiler water has a PH of .5 what compound type do you add to neutralize it? - Correct Answer-BASES - THEY REACT WITH ACIDS TO FORM A SALT

What level of deionized water alkalinityis permitted for a 600 psi boiler? - Correct Answer-250 PPM What can oxygen cause in a system - Correct Answer-PITTING CORROSION In a vertical boiler where is the first place to check for thinning tubes? - Correct Answer-WATER LEGS especially at the bottom or on the combustion side at the upper ends of the tubes. What produces soft scale? - Correct Answer-Calcium and magnesium carbonate and magnesium clorine Hideout in a boiler causes what to precipitate? - Correct Answer-Sodium phosphate What is main cause of a generating tube failure? - Correct Answer-overheating at the lower tubes due to scale sludge and poor circulation

What refrigerant is flammable and non toxic? - Correct Answer-Propane What refrigerant class is Ammonia R 717? - Correct Answer-B2 What is the purpose of a condensor in a refrigerant system? - Correct Answer-to bring refrigerant to a liquid state Why is oil in a refrigerating system? - Correct Answer- lubricates and cools compressor How is moisture removed from a refrigerant system? - Correct Answer-filter dryer What type of gas DONT you use to leak test an AC system? - Correct Answer-OXYGEN What is the maximum voltage on a boiler control circuit? - Correct Answer-150 VOLTS A fuel oil that has an API of 32 has how many btus per lb of heating? - Correct Answer-19490

Which fuel oils need heating? - Correct Answer-#4;#5;#6 What size pipe is used as a header in a boiler operating at 100 psi? - Correct Answer-6 inches What function can an operator contribute towards boiler function? - Correct Answer-saftey - efficiency - log plant readings How is heat transferred in a boiler? - Correct Answer- CONVECTION - CONDUCTION - RADIATION What is not an organic sludge conditioner? - Correct Answer- Amines Which by-product has the largest heating value? - Correct Answer-Butane An increase in 10-20 degrees can reduce creep life by how manuy years - Correct Answer-10-20

which coal burns with a yellow flame? - Correct Answer- Bituminous What nondestructive testing is best for testing thickness of plates and tubes? - Correct Answer-Ultrasound On a 2"valve auxillary staem what valves are needed? - Correct Answer-Single supply OS&Y What are the min and max size of a safely valve per code for boilers? - Correct Answer-Min 3/4 and max 4 1/2 What stamp is put on a safety valve after its been repairs? - Correct Answer-VR stamp How often do you test your float controls on a hot water boiler? - Correct Answer-Weekly How often do you test a safety valve with pressure? - Correct Answer-Annually

How often do you test a safety valve with a lever test? - Correct Answer-Monthly This part of the safety valve works in conjunction with the adjusting ring to allow it to pop open. - Correct Answer- Huddling Chamber What do you do if a safety valve is leaking? - Correct Answer- Reground seat A safety valve discharge pipe should go how high when workers maybe present? - Correct Answer-6 feet high If 2 safety valves are used with the same discharge pipe the discharge line must have - Correct Answer-The same area as both valves area Every discharge valve should have what size drain? - Correct Answer-3/8 to 1/2 drain What are the Blowback setting on a safety valve? - Correct Answer-Up to 4% but not less than 2 lbs