Questions and Answers
EASY What is the consequence of cracks in tube ends and tube sheets?
Create hazardous operating conditions
What is the indication of a larger crack in the boiler?
Increase in make-up water
What should be done when there are signs of a tube leak during operation?
Shut down the boiler immediately
Where may water be noticed dripping for firetube boilers with larger leaks?
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What is the sign of a leak when the boiler is opened up for annual maintenance?
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Why are cracks in tube ends and tube sheets hard to detect?
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Why is careful inspection of tube ends and tube sheets required?
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What is the purpose of several methods developed to detect cracks?
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What is the primary purpose of cleaning the surfaces of tube ends and tube sheets in the dye-penetrant method?
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What happens to the penetrant in the cracks after the developer is applied?
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What is the advantage of using portable spray-on dye-penetrant kits?
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What is the common name for invisible light in the ultraviolet range of wavelengths?
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What happens to the penetrant in the cracks when black light is aimed at the area?
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What is the purpose of the developer in the dye-penetrant method?
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MEDIUM Why do tube sheet cracks and tube leaks need to be repaired immediately?
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What is a helpful tool in detecting larger cracks in boilers?
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What is a possible indication of a larger crack in a boiler?
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What is a common location where water may be noticed dripping for firetube boilers with larger leaks?
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What is the purpose of shutting down the boiler when there are signs of a tube leak?
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What is a common sign of a leak when the boiler is opened up for annual maintenance?
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Why are cracks in tube ends and tube sheets difficult to detect?
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Why is careful inspection of tube ends and tube sheets required?
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What is the primary purpose of applying a special penetrating dye in the dye-penetrant method?
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What is the function of the developer in the dye-penetrant method?
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Why are portable spray-on dye-penetrant kits widely used?
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What is the effect of black light on the penetrant in the fluorescent dye penetrant method?
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What is the purpose of cleaning the surface of tube ends and tube sheets in the dye-penetrant method?
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What happens to the crack indication on the surface when the developer is applied in the dye-penetrant method?
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HARD What is the primary reason why the surfaces of tube ends and tube sheets must be thoroughly cleaned in the dye-penetrant method?
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What is the key characteristic of the penetrant used in the fluorescent dye penetrant method?
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What is the primary advantage of using the fluorescent dye penetrant method over the traditional dye-penetrant method?
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What is the purpose of the developer in the dye-penetrant method?
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What is the primary benefit of using portable spray-on dye-penetrant kits?
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What is the critical step that must be performed after the penetrant is applied to the surface in the dye-penetrant method?
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What is the primary reason why tube sheet cracks and tube leaks should be repaired as soon as possible?
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Why are water meters installed on the make-up system helpful in detecting larger cracks in boilers?
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What is the purpose of closing the stop valves on the steam outlet and supply and return lines when shutting down the boiler due to a tube leak?
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Why are tube leaks often undetectable during boiler operation?
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What is the significance of a white mineral deposit on the boiler's surface during annual maintenance?
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Why are cracks in tube ends and tube sheets often difficult to detect with the naked eye?
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What is the primary purpose of inspecting tube ends and tube sheets during boiler shutdown?
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What is the significance of hearing steam hissing from the boiler when it cycles off?
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Study Notes
Boiler Tube Leaks and Cracks
- Cracks in tube ends and tube sheets weaken boiler structures, creating hazardous operating conditions.
- Tube sheet cracks and tube leaks should be repaired immediately to prevent boiler water escape.
Identifying Leaks
- An increase in make-up water to the boiler indicates a larger crack.
- Water meters installed on the make-up system help detect leaks.
- Steam hissing from the boiler when it cycles off may indicate a large leak.
- Drips at the front and rear doors of firetube boilers may occur when the boiler cycles off.
- Water dripping on the floor by the boiler indicates a large leak.
Shutting Down the Boiler
- Immediately shut down the boiler when signs of a tube leak appear during operation.
- Close the stop valve on the steam outlet for steam boilers.
- Close the stop valves in the supply and return lines for hot water boilers.
- Maintain the normal water level in the boiler until it cools down.
Detecting Leaks During Maintenance
- Smaller leaks may not be noticeable during operation but can be seen as a white mineral deposit during annual maintenance.
- Cracks often develop over a long period without visible signs, making regular inspection crucial.
Detection Methods
Dye-Penetrant Method
- Clean the surfaces of tube ends and tube sheets thoroughly.
- Apply a special penetrating dye by brushing or spraying.
- Remove excess penetrant and apply a thin coating of developer.
- The crack will show as a red indication on the white developer background.
Fluorescent Dye Penetrant
- Use black light to detect tiny cracks.
- Apply fluorescent penetrant to the cleaned area.
- Remove excess penetrant and apply developer.
- Use black light to make the cracks visible through fluorescence.
Boiler Tube Leaks and Cracks
- Cracks in tube ends and tube sheets weaken boiler structures, creating hazardous operating conditions.
- Tube sheet cracks and tube leaks should be repaired immediately to prevent boiler water escape.
Identifying Leaks
- An increase in make-up water to the boiler indicates a larger crack.
- Water meters installed on the make-up system help detect leaks.
- Steam hissing from the boiler when it cycles off may indicate a large leak.
- Drips at the front and rear doors of firetube boilers may occur when the boiler cycles off.
- Water dripping on the floor by the boiler indicates a large leak.
Shutting Down the Boiler
- Immediately shut down the boiler when signs of a tube leak appear during operation.
- Close the stop valve on the steam outlet for steam boilers.
- Close the stop valves in the supply and return lines for hot water boilers.
- Maintain the normal water level in the boiler until it cools down.
Detecting Leaks During Maintenance
- Smaller leaks may not be noticeable during operation but can be seen as a white mineral deposit during annual maintenance.
- Cracks often develop over a long period without visible signs, making regular inspection crucial.
Detection Methods
Dye-Penetrant Method
- Clean the surfaces of tube ends and tube sheets thoroughly.
- Apply a special penetrating dye by brushing or spraying.
- Remove excess penetrant and apply a thin coating of developer.
- The crack will show as a red indication on the white developer background.
Fluorescent Dye Penetrant
- Use black light to detect tiny cracks.
- Apply fluorescent penetrant to the cleaned area.
- Remove excess penetrant and apply developer.
- Use black light to make the cracks visible through fluorescence.
Boiler Tube Leaks and Cracks
- Cracks in tube ends and tube sheets weaken boiler structures, creating hazardous operating conditions.
- Tube sheet cracks and tube leaks should be repaired immediately to prevent boiler water escape.
Identifying Leaks
- An increase in make-up water to the boiler indicates a larger crack.
- Water meters installed on the make-up system help detect leaks.
- Steam hissing from the boiler when it cycles off may indicate a large leak.
- Drips at the front and rear doors of firetube boilers may occur when the boiler cycles off.
- Water dripping on the floor by the boiler indicates a large leak.
Shutting Down the Boiler
- Immediately shut down the boiler when signs of a tube leak appear during operation.
- Close the stop valve on the steam outlet for steam boilers.
- Close the stop valves in the supply and return lines for hot water boilers.
- Maintain the normal water level in the boiler until it cools down.
Detecting Leaks During Maintenance
- Smaller leaks may not be noticeable during operation but can be seen as a white mineral deposit during annual maintenance.
- Cracks often develop over a long period without visible signs, making regular inspection crucial.
Detection Methods
Dye-Penetrant Method
- Clean the surfaces of tube ends and tube sheets thoroughly.
- Apply a special penetrating dye by brushing or spraying.
- Remove excess penetrant and apply a thin coating of developer.
- The crack will show as a red indication on the white developer background.
Fluorescent Dye Penetrant
- Use black light to detect tiny cracks.
- Apply fluorescent penetrant to the cleaned area.
- Remove excess penetrant and apply developer.
- Use black light to make the cracks visible through fluorescence.
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