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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? – Answers 7 feet On a gas fired boiler what is the proper gas to air mixture - Answers30%-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? - ANSWER s= (CA x 2.5) + (Mg x 4.1)\notch= (60 x 2.5) + (18 x 4.1)\notch= 150+73.8 = (223.8 PPM) How often should a complete external inspection of the boiler be done? - ANSWER s Once a Shift With 24 hr. operation how often do you check the water level? - ANSWER s Once per shift How often do you check the LWCO? - ANSWER s Once per shift How often do you check the High Limit Switch? - ANSWER s Annually A 2" pipe was found to be delivering water at 100 Pisa at 1040ft per second. How many gallons per hour will it deliver? – ANSWERs GPM= V (diameter squared) divided by .4085 ANSWER 469 BOG What controls the amount of blowback on a safety valve? - ANSWER sBlowback ring or adjusting ring On an open air expansion tank hot water boiler system; how high should it be mounted?
- ANSWER s (4 Feet) above the highest heating element. What is the minimum top clearance of boilers with manholes? - ANSWER s5 feet Package boilers; steam heating boilers and hot water heating boilers shall have a minimum clearance of? - ANSWER s2 feet from ceiling. Code chapter 10 page Most important safety device on a boiler? - ANSWER s Safety relief valve
What does a Black Liquor Boiler do? - ANSWER s Black Liquor is the byproduct of wood pulp processing in the paper making industry. What does Black liquor boiler known for? - ANSWER s Steam generation and recovery of soda ash Maximum line voltage for control on a boiler? - ANSWER s150 volts Under what code are boilers designed and constructed? - ANSWER sASME- CSD 1 How many low water cut offs are needed per code for a hot water system when a boiler has inputs greater than 400,000 but per hr. - ANSWER s1 LWCO is needed. What is the minimum and maximum size for a safety valve per code for boilers? - ANSWER s Minimum 3/4" and Maximum 4 1/2" What stamp is put on a boiler after repairs? - ANSWER s’" What is the equalizing system used for? - ANSWER s The equalizing system is for warming up the steam lead. A blow down valve is located at the lowest water space of a boiler for three purposes - ANSWER s1. 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? - ANSWER s Electronic After opening a boiler for repairs how much oxygen is needed? - ANSWER s19% What is the first thing you do when shutting down a boiler? - ANSWER s Turn off (extinguish fire) What is the legal limit of acceptable asbestos particles? - ANSWER s0.1 fibers per cubic centimeter What is CREEP? - ANSWER s 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? - ANSWER s14000 but/lb. What substance transfers electrical current in a photocell? - ANSWER s Electricity will flow when the CADMIUM is exposed to sufficient light.
Which chemical is used to combat scale? - ANSWER s Combined phosphate treatment- sodium phosphate Other than sulfite what chemical is used to combat corrosion in boilers? - ANSWER s Hydrazine What will neutralize acid? - ANSWER s Alkali and Lime Soda What mechanical device is used to remove scale from fire tubes? - ANSWER s tube rattler or vibrator What percentage of the pressure should a boiler have before you test the lever of a safety valve? - ANSWER s75% Where is internal corrosion most likely to occur on a vertical tube boiler? - ANSWER s Water leg-Mud leg What are the minimum and maximum sizes permitted for blow down valves or connections? - ANSWER s3/4"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? - ANSWER s½ " feed ¾ " blow off How often should water columns and water glass levels be checked on a high pressure boiler? - ANSWER s (Once A Shift)\Nat the beginning of each shift - beginning of the work effort What takes no actual action chemical part in combustion? - ANSWER s Nitrogen How many ppm of EDTA are needed to tie up 1ppm of hardness? - ANSWER sEDTA 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? - ANSWER s6 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? - ANSWER s Grade 1 (Number 1) How often should you test the operating control? - ANSWER s Annually How often should the testing and inspecting of the burner component? - ANSWER s Annually A lead sulfite photocell is what type of flame sensor? - ANSWER s Infrared light sensing
What is the least amount of oxygen needed when a nitrogen blanket is used? - ANSWER s19% How should a boiler be prepared for inspection? - ANSWER s 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 - handhold 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; blow down; 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? - ANSWER s) 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 handholds on a boiler for? - ANSWER s Examination or cleaning How do you protect a steam boiler? - ANSWER s Safety valve How to you protect a pressure vessel? - ANSWER s Pressure relief valve How do you protect a hot water boiler? - ANSWER s Pressure relief valve What gages are on a steam boiler? - ANSWER s Water gage glass and pressure gage Methods used to control the temperature of a superheated? - ANSWER s 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? - ANSWER s Disodium phosphate and disodium phosphate What chemical compounds in water cause permanent hardness? - ANSWER s Calcium sulfate and magnesium sulfate What factors must be taken into consideration when choosing a control for a boiler? - ANSWER s6 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
Boilers having more than 500square feet of heating surface should have how many means of feed water? - ANSWER s Types of FEEDWATER REGULATORS - ANSWER s1.Thermostatic mechanical regulator 2. Thermostatic fluid style 3. Float operated style Name two types of commonly used feed water pumps - ANSWER s Injector and Inspiratory What piping arrangement is used to return condensate from steam lines and steam separators? - ANSWER sHOLLYLOOP What would happen if high temp liquid passes through a centrifugal pump? - ANSWER s WIRE DRAWING A multi stage pump can be either __________ or_______? - ANSWER s Volute or Diffuser To prevent cavitation most pumps are stamped with the ____ _______ _______ ____?
- ANSWER s NET POSITIVE SUCTION HEAD What are two types of condensate return systems?? - ANSWER s.) 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 - ANSWER s 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 primed? - ANSWER s 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? – ANSWERs RECIPRICATING What causes a piston type trap to open? - ANSWER scold condensate (on test the steam psi drop and temp drop was used) Quickly opening a steam valve will cause _______ ________. - ANSWER s water hammer What mechanical device removes scale from a water tube boiler? - ANSWER s tube turbine
What causes blistering? - ANSWER s slag inclusion forming a lamination at the time the plate was rolled in the steel mill and it's actually a separation of metal from the shell plate caused by impurities rolled into the shell plate when it was formed. To internally remove oxygen from the boiler use______ ________. - ANSWER s Sodium Sulfite A positioning control system is used on a ______ ________ - ANSWER s process boiler A say bolt universal is a - ANSWER s measurement of viscosity Creep gets worse with _______________ __________ - ANSWER s elevated temps What type of valve WOULD NOT be a good choice if sediment were present - ANSWER s GLOBE How many buts does it take to take 10 lbs. of steam from 40 to 41 degrees - ANSWER s10 buts 1btu=1lb What is it called when you let a piece of equipment fail before you repair/replace it? - ANSWER s Breakdown maintenance What percent of blistering or budging is ok? - ANSWER s2% What kind of boiler are stay bolts found on? - ANSWER s Fire tube boilers An 8 foot length of tube or shell can take up to ___% sag or bend and still be used without replacing? - ANSWER s2% What does a low water cutoff do in a low water condition? - ANSWER s Shuts off fuel supply What is the first indication of a low water condition - ANSWER s red hot crown sheet If a boiler exceeds 100psi it must have how many blow downs? - ANSWER s What is the appropriate test for checking porosity of the metal? - ANSWER s PULSE ECHO (A TYPE OF ULTRASONIC) What chemicals are used to combat corrosion? - ANSWER s Sodium Sulfite; hydrazine; catalyzed hydrazine If your boiler water has a PH of .5 what compound type do you add to neutralize it? – ANSWERs BASES - THEY REACT WITH ACIDS TO FORM A SALT
What is not an organic sludge conditioner? - ANSWER s Amines Which by-product has the largest heating value? - ANSWER s Butane An increase in 10-20 degrees can reduce creep life by how many years - ANSWER s10- 20 which coal burns with a yellow flame? - ANSWER s Bituminous What nondestructive testing is best for testing thickness of plates and tubes? - ANSWER s Ultrasound On a 2"valve auxiliary steam what valves are needed? - ANSWER s Single supply OS&Y What are the min and max size of a safety valve per code for boilers? - ANSWER s in 3/4 and max 4 1/ What stamp is put on a safety valve after its been repairs? - ANSWER s stamp How often do you test your float controls on a hot water boiler? - ANSWER s Weekly How often do you test a safety valve with pressure? - ANSWER s Annually How often do you test a safety valve with a lever test? - ANSWER s Monthly This part of the safety valve works in conjunction with the adjusting ring to allow it to pop open. - ANSWER s Huddling Chamber What do you do if a safety valve is leaking? - ANSWER s Reground seat A safety valve discharge pipe should go how high when workers maybe present? - ANSWER s6 feet high If 2 safety valves are used with the same discharge pipe the discharge line must have - ANSWER s The same area as both valves area Every discharge valve should have what size drain? - ANSWER s3/8 to 1/2 drain What is the Blowback setting on a safety valve? - ANSWER s Up to 4% but not less than 2 lbs. Safety valve plate has; - ANSWER s Manufacturer’s name or trade mark- type or design# - Size - seat dial - set pressure -blow down - 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? - ANSWER s75% On an open air expansion tank hot boiler system; How high should it be mounted? - ANSWER s4 feet above the highest heating element. What is the minimum clearance of boilers without manhole covers on top? - ANSWER s2 ft. Under what code are oil fired boilers & their control systems covered? - ANSWER s Listed & labeled in accordance with UL 726.NFPA 8501 How high is a pull station mounted on a wall? - ANSWER s48 inches When working in a boiler; work permits should be acquired? - ANSWER s For the work shift. To inspect a boiler they must be what? - ANSWER s Be employed either by the state or by an insurance company licensed to write boiler and pressure vessel insurance in that jurisdiction ASME CSD 1 requires the main gas burners train to have what? - ANSWER s2 manual safety shutoff valves Welds must be approved and witnessed who? - ANSWER s Authorized inspector. Hydrostatic test is done at what pressure? - ANSWER s1.5 times the MAWP or 50% over MAWP During a hydro test if the boiler leaks who do you notify? - ANSWER s 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? - ANSWER s 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 blow down valves or connection? - ANSWER s1 min & 2-1/2 max If a boiler has 1" blow down pipe; what diameter should the boiler blow down tank air vent should be? - ANSWER s2.5" What are 3 low water cutouts? - ANSWER s (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)
A solid that is separated from a solution is a_________________. – ANSWERs precipice All impurities are in one of four states – ANSWERs they are ________; __________; _________; and _________. The capacity of a substance to combine with another substance is its _____________. - ANSWER s Valence Calcium and Magnesium bicarbonate produce ___________ hardness. - ANSWER s temporary Scale that is soft and muddy similar to magnesium carbonate is___________________.
- ANSWER s calcium carbonate In order to prevent corrosion - ANSWER s boiler water pH is maintained between ________________. __________ _________ is used to internally remove oxygen from the boiler. - ANSWER s sodium sulfite In order to remove one pound of oxygen - ANSWER s it takes ________ lbs. of sodium sulfate. __________ 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. - ANSWER s amines When boiler water has high levels of solids; steam bubbles can be trapped below the water line causing water level fluctuations known as __________. - ANSWER s Foaming ___________ is when water impurities leave the boiler with the steam. - ANSWER s carryover The loss of metal that forms smooth - ANSWER s rolling contour as a result of an acid attack is called __________. __________ blow down lowers the TDS level in the boiler. - ANSWER s surface The electrolytic flow between dissimilar metals in a waterborne environment which results in localized corrosion is known as _____________. - ANSWER s galvanic action The_______ _______ or______ _______ _______ sense heat to prove flame in a boiler. - ANSWER s Stack switch - rectifying flame rod
Rectifying phototubes and cadmium sulfide phototube both prove flame in the boiler by sensing __________ ________. - ANSWER s Visible light The chief heat producing elements in fuels are_____; ______ and__________. - ANSWER s carbon hydrogen sulfur The presence of _________ in flue gas is an indication of incomplete combustion. - ANSWER s Carbon monoxide The EPA limits the amount of particulate emission to ________ pounds per 1 000 000 but’s input. - ANSWER s. When Knox combines with organic gases ________ is produced. - ANSWER s Ozone Anthracite coal is very hard and has a high percentage of fixed________ and a heating value of ________but’s per pound. - ANSWER s fixed carbon - 14000 __________ is the lowest grade of coal; has a claylike appearance and a heating value range of _______ two _______but’s per lb. – ANSWERs Lignite 7000 to 11000 but’s per lb. Spreader and chain grate stokers are types of ___________ stokers - ANSWER s over feed #2 fuel oil is classified as _________ domestic fuel oil. - ANSWER s medium #6 fuel oil is also known as?? - ANSWER s Bunker C #4 fuel oil has about________ but’s per lb. - ANSWER s Which fuels require heading prior to being sprayed into a furnace? - ANSWER s4; 5; 6 As the temperature of a fuel oil rises; the viscosity goes_____. - ANSWER s Down What burner can burn almost any fuel at any temperature?? - ANSWER s steam atomizing Steam atomization typically consumes about ____ percent of the steam produced by the boiler. - ANSWER s2% An air atomizing burner requires______psi air pressure above the oil pressure when burning heavy oil. - ANSWER s Flame impingement on the metal surfaces of the boiler can cause the metal to ______ and ______. - ANSWER s overheat; bulge
GPM formula – ANSWERs GPM=VxDsquared/. Capacity formula – ANSWERs GPM=LANE/ A steam pressure gauge has a _____ to protect against the high _________ of the steam. - ANSWER s siphon - temperature A cross or tee connection to the boiler drum used exclusively for attaching a test pressure gauge is known as - ANSWER s inspectors connection A ________thermometer uses two dissimilar metals that bend predictably with a change in temp. – ANSWERs BIMETALIC Minimum size for the connection between the gauge glass and the water column is _______ - ANSWER s1/2" 2 or more safety valves are required on a boiler with a heating surface in excess of ______square feet or electric impute of ________KW - ANSWER s500 sq. ft. ; 500KW Safety valves on a superheated should be set _____than the safety valve on the steam drum - ANSWER s lower Boiler stop valves over 2 inches in diameter should be ___ _______ ___ ______. – ANSWERs OS&Y When boiler pressure exceeds _____psi; two blows down valves must be used; one must be a slow opening valve - ANSWER s Slow opening blow down valves must complete ___turns between full open and full shut. - ANSWER s A COPES feed water regulator is an example of a ________ ____________type feed water regulator. - ANSWER s thermostatic mechanical The feed water 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 - ANSWER s PRESSURE The 3 element feed water regulator senses ________ _________ AND_________. - ANSWER s steam flow - feed water flow - and water level The _______ ________uses boiler water to complete the electrical circuit - ANSWER s submerged electrode The submerged electrode does not have a __________ _______. - ANSWER s mercury switch
2 types of electric boilers - ANSWER s RESISTANCE and ELECTRODE Electric current flows through the water and converts electrical energy to heat energy in the ________type boiler - ANSWER s ELECTRODE A high voltage steam electrode has voltage between _____ AND_________ - ANSWER s2300 and 15000 Volts A high voltage steam electrode boiler has ___ generating compartments; one for each phase. - ANSWER s The capacity of a safety valve on an electric boiler is __ lbs. per KW or ___ buts per hr. per KW - ANSWER s3.5 LBS - 3500btus per KW An HTHW system has better temp control because it has a large _______ _______ ________. - ANSWER s heat storage capacity Down herm thermal liquid systems use ________ _____________ at tubes to prevent leaking - ANSWER s welded joints __________ ________ boilers recover heat in the exhaust from a gas turbine to produce useful steam - ANSWER s WASTE HEAT When exhaust gasses don’t have enough energy to produce the final steam pressure _______ ________ is used. - ANSWER s SUPPLEMENTAL FIRING A recovery steam generator converts steam energy to mechanical energy to produce electricity in a ________ ________ plant. - ANSWER s COMBINED CYCLE ___________ ___________Sell steam to local industrial plants and surplus electric to local utilities - ANSWER s COGENERATION PLANTS Superheated steam is injected into a gas turbine to increase electrical output in the ______ _____________. - CYCLE Waste products from sugar cane are used in a BAGASSE plant. When dried it has a heating value of ________ two _________ buts per lb. - ANSWER s8000 to 8700 buts per lb. Black Liquor boilers are known for - ANSWER s STEAM GENERATION and production of SODA ASH For black liquor boilers to sustain combustion - ANSWER s they must contain _______ % solids.
Stress imposed on a boiler by a sudden drastic change in temp. - ANSWER s Thermal Shock Gauge pressure + atmospheric pressure - ANSWER s Absolute pressure Tubes exposed to the highest temps in the furnace and contain rising water are? - ANSWER s riser tubes _____________tubes contain cooler descending water replenish water to riser tubes - Manholes are __________in shape – ANSWERs ELIPTICAL Handholds are generally __" by ___" - ANSWER s4"x5" 2 methods of supporting an HRT - ANSWER s1.) lug and roller 2.) overhead suspension Advantages of Water tube boilers - ANSWER s1. higher capacity 2. drum not exposed to the radiant heat of the fire. ??????____ cubic inches in 1 gallon - ANSWER s A _______ _______ is constructed of flat plates referred to as a tube sheet and a tube cap sheet. - ANSWER s BOX HEADER Bent tubes are more________ than straight tubes. Bent tubes allow for free expansion and contraction. - ANSWER s flexible ____________prevents the tube ends from being overheated - ANSWER s Beading When a furnace baffle breaks the gasses short circuit causing excessive ______________. – ANSWERs flue gas temps Welding flat strips of metal between the water wall tubes is known as _________ ____________ construction. - ANSWER s membrane wall The amount of pressure below the set point that must be relieved before a safety valve closes - ANSWER s BLOWBACK ________ are used instead of elbows on water column piping to allow for internal inspection. - ANSWER s Crosses When using a lift lever to manually test a safety valve - ANSWER s the boiler pressure must be ____% of the safety valve set point Under what code are oil fired boilers & their control systems covered? - ANSWER s Listed & labeled in accordance with UL 726.NFPA 8501; 8502; 8504
Hydrostatic test is done at what pressure? - ANSWER s150 times the MAWP or 50% over MAWP What are 3 low water cutouts? - ANSWER s (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) Blow down shall not be less than __ or lower than __ of the safety valve? - ANSWER less than 2 lbs. or lower than 96% of the safety valve. What are 3 types of feed water regulators: - ANSWER s Thermostatic-mechanical regulator; Thermostatic-fluid type; Float operated style On a piston type trap what would cause it to open? - ANSWER scold Condensate ANSWER s on test was steam psi drop and temp drop If you open or close a steam stop valve to quick it will cause what? - ANSWER s Water Hammer What are two types of commonly used feed water pumps - ANSWER s Injectors and Inspiratory? What is blistering caused by? - ANSWER s 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 ______________. - ANSWER s localized corrosion; stress concentration What compound is not a heat producer? - ANSWER s Nitrogen How many types of flame detectors are there? - ANSWER s6 Types On a package boiler; how many ways could cause fire puffs when it is starting up? - ANSWER s6 ways Air is _____% oxygen by weight & ______% by volume. - ANSWER s Air is 23% oxygen by weight & 21% by volume. The hard grove index is a measurement of___________. – ANSWERs Grind ability How many pounds of oxygen are required to properly burn 1 pound of methane? - ANSWER s4 lbs. of oxygen
