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EASY What material are hot water heating boilers commonly made of?

  • Copper tubing, cast iron, and steel (correct)
  • Aluminum, copper, and glass
  • Cast iron, steel, and wood
  • Copper, steel, and bronze

    • What should be done with atmospheric burners during the off-season?

  • Clean them with a wire brush
  • Replace them with new ones
  • Cover the burner tubes to protect them from dust (correct)
  • Leave them uncovered

    • What should be done to the fireside surfaces of the boiler during extended non-operating periods?

  • Clean them with a wire brush
  • Leave them as is
  • Apply a light coating of oil (correct)
  • Apply a thick coating of oil

    • What should be checked for cracks, corrosion, and signs of leakage?

    <p>Ductwork, breeching, piping, and pipe fittings</p> Signup and view all the answers

    What should be done to the boiler at the end of the heating season?

    <p>Do not drain the hot water boiler and heating system</p> Signup and view all the answers

    How should cast iron steam boilers be prepared for annual shutdown and maintenance?

    <p>Use the procedure for steel steam boiler maintenance</p> Signup and view all the answers

    What should be done to the boiler before placing it back in service after wet layup?

    <p>Drain the water down to normal operating water level</p> Signup and view all the answers

    When should cast iron steam boilers be left empty (dry layup)?

    <p>Only if the shutdown period is expected to be long term or if freezing conditions are expected</p> Signup and view all the answers

    How should power boilers be maintained?

    <p>Like hot water heating boilers</p> Signup and view all the answers

    What should be done to the boiler while it is in operation and under pressure?

    <p>Open the bottom blowoff connections one at a time</p> Signup and view all the answers

    What is the first step in cleaning the tubes and tubesheets?

    <p>Remove the flame retarders</p> Signup and view all the answers

    How often do standard ball bearings typically require lubrication?

    <p>Once a year</p> Signup and view all the answers

    What should be done to refractory cracks?

    <p>Cover them with a diluted heat resistant cement</p> Signup and view all the answers

    What is a good indication of a clean burner?

    <p>A symmetrical flame</p> Signup and view all the answers

    How often should gas burners be cleaned and inspected?

    <p>Once a year</p> Signup and view all the answers

    What should be used to remove carbon build-up from the nozzle?

    <p>A monarch brass wire brush</p> Signup and view all the answers

    What should be done to the fuel lines before removing the burner assembly?

    <p>Lock the manual stop valves closed</p> Signup and view all the answers

    Why should the door gaskets be covered with graphite and oil or an anti-seize compound?

    <p>To make future opening easier</p> Signup and view all the answers

    What should be done to the scanner tube during cleaning?

    <p>Run a cloth through it to keep it clean and shiny</p> Signup and view all the answers

    What should be done after reassembling the burner assembly?

    <p>Replace the burner in the burner head</p> Signup and view all the answers

    When should you operate the safety valve try-lever?

    <p>When the boiler is under pressure</p> Signup and view all the answers

    Why should you not open power boiler safety valves with the try-lever when the steam pressure is less than 75% of the set pressure?

    <p>To prevent safety valve damage</p> Signup and view all the answers

    What should be done to the burner tubes of boilers with atmospheric burners during the off-season?

    <p>Cover them to protect from dust</p> Signup and view all the answers

    How should you clean the boiler fireside heating surfaces?

    <p>With a wire brush and a vacuum cleaner</p> Signup and view all the answers

    Why should you apply a light coating of oil to the fireside surfaces?

    <p>To prevent corrosion during extended non-operating periods</p> Signup and view all the answers

    What should you do after draining the boiler?

    <p>Remove cleanout openings, washout plugs, handholes, and manholes</p> Signup and view all the answers

    What should you do if hard scale is baked on the internal surfaces of the boiler?

    <p>Consult with a reputable water treatment representative</p> Signup and view all the answers

    Why should you dry the boiler waterside thoroughly prior to inspection?

    <p>To ensure the boiler is safe for inspection</p> Signup and view all the answers

    What should be done to power boilers in steam service if they are out of service for long periods of time?

    <p>Leave them in dry layup</p> Signup and view all the answers

    What should be done to condensate return piping?

    <p>Inspect it for cracks, corrosion, and signs of leakage</p> Signup and view all the answers

    What should boiler operators watch for in steam and water connections?

    <p>Leaks</p> Signup and view all the answers

    Why should leaks be repaired as soon as they are noticed?

    <p>To prevent erosion of sealing surfaces</p> Signup and view all the answers

    What is the recommended frequency for inspecting boiler feed pump or hot water circulating pump packing glands?

    <p>Weekly</p> Signup and view all the answers

    Why should gland nuts be tightened only enough to prevent excessive leakage?

    <p>To prevent drying out of packing</p> Signup and view all the answers

    What should be done to new boilers after the first three months of operation?

    <p>Shut down, drained, opened up, flushed out, and inspected</p> Signup and view all the answers

    Why should the tightness of packing glands, flange bolts, handhole and manhole yokes, and unions be periodically checked and adjusted?

    <p>To prevent leaks</p> Signup and view all the answers

    What should be inspected for scale formation and pitting?

    <p>Boiler tubes and tube sheets</p> Signup and view all the answers

    How should firetubes with soot coating be cleaned?

    <p>By brushing</p> Signup and view all the answers

    MEDIUM What should be done to new boilers after the first three months of operation?

    <p>Shut down, drained, opened up, flushed out with a high-pressure hose, and inspected</p> Signup and view all the answers

    What should be done to prevent drying out of packing and scoring of the shaft in pumps with packing glands?

    <p>Tighten the gland nuts enough to prevent excessive leakage, allowing a few drops per minute</p> Signup and view all the answers

    Why should boiler operators watch for leaks in steam and water connections?

    <p>To prevent erosion of sealing surfaces and possible injury</p> Signup and view all the answers

    What should be inspected for scale formation and pitting?

    <p>Tubes and tube sheets</p> Signup and view all the answers

    Why should leaks in gauge glass packing be repaired as soon as possible?

    <p>To prevent gauge glass failure and possible injury</p> Signup and view all the answers

    How often should the tightness of packing glands, flange bolts, handhole and manhole yokes, and unions be checked and adjusted?

    <p>Periodically</p> Signup and view all the answers

    What should be done to prevent leaks in steam and water connections?

    <p>Inspect and adjust the tightness of packing glands, flange bolts, handhole and manhole yokes, and unions</p> Signup and view all the answers

    Why should confined space entry procedures be followed?

    <p>To ensure safe entry into confined spaces</p> Signup and view all the answers

    What is the minimum steam pressure required to open power boiler safety valves with the try-lever?

    <p>75% of the set pressure of the safety valve</p> Signup and view all the answers

    What should be done to the boiler fireside heating surfaces during extended non-operating periods?

    <p>Apply a light coating of oil</p> Signup and view all the answers

    Why should the boiler waterside be dried thoroughly prior to inspection?

    <p>To prevent corrosion</p> Signup and view all the answers

    What should be done to the burner tubes of boilers with atmospheric burners during the off-season?

    <p>Cover them to protect from dust</p> Signup and view all the answers

    What should be done to the boiler after it cools down?

    <p>Drain it after it cools down</p> Signup and view all the answers

    Why should you not open power boiler safety valves with the try-lever when the steam pressure is less than 75% of the set pressure?

    <p>It may damage the valve</p> Signup and view all the answers

    What should be done to the condensate return piping?

    <p>Inspect it for cracks and corrosion</p> Signup and view all the answers

    What should be done to power boilers in steam service if they are out of service for long periods of time?

    <p>Leave them in dry layup</p> Signup and view all the answers

    What should be done to the gauge glass connections?

    <p>Clean them out if necessary</p> Signup and view all the answers

    Why should the low water cutoff float and switches be examined?

    <p>To ensure they are in good condition</p> Signup and view all the answers

    What is the recommended procedure for removing impurities from a hot water heating boiler?

    <p>Briefly open the boiler drain cocks one at a time, removing impurities and draining several gallons of water</p> Signup and view all the answers

    Why is it important to clean the vent connector and breeching during annual maintenance?

    <p>To prevent corrosion of the boiler surfaces, ductwork, and breeching during the off-season</p> Signup and view all the answers

    What should be done to the fuel valves during the off-season?

    <p>Close and lock out all fuel valves</p> Signup and view all the answers

    What is the recommended procedure for preparing a cast iron steam boiler for annual shutdown and maintenance?

    <p>Follow the procedure for steel steam boiler maintenance</p> Signup and view all the answers

    Why should the firing circuit be disabled and locked out during the off-season?

    <p>To prevent accidental firing of the boiler during the off-season</p> Signup and view all the answers

    What should be done to the boiler's ductwork, breeching, piping, and pipe fittings during annual maintenance?

    <p>Check the ductwork, breeching, piping, and pipe fittings for cracks, corrosion, and signs of leakage</p> Signup and view all the answers

    What should be done to the low water cut-off float assembly during annual maintenance?

    <p>Blow sediment and debris from the base of the low water cut-off float assembly</p> Signup and view all the answers

    Why is it important to apply a light coating of oil to the fireside surfaces during extended non-operating periods?

    <p>To protect the fireside surfaces from corrosion</p> Signup and view all the answers

    What is the recommended procedure for maintaining power boilers in steam service?

    <p>Take the power boilers out of service and maintain them like hot water heating boilers</p> Signup and view all the answers

    Why is it important to follow the manufacturer's recommendations for boiler maintenance?

    <p>To ensure that repairs are made to defective controls during the off-season</p> Signup and view all the answers

    What should be done before cleaning the tubes and tubesheets?

    <p>Remove the flame retarders</p> Signup and view all the answers

    What is the purpose of covering the door gaskets with graphite and oil or an anti-seize compound?

    <p>To make future opening easier</p> Signup and view all the answers

    How often should sealed bearings typically be lubricated?

    <p>Every three years</p> Signup and view all the answers

    What should be used to repair refractory cracks?

    <p>Gunnable refractory materials</p> Signup and view all the answers

    What should be observed regularly during boiler operation to indicate a clean burner?

    <p>The burner flame symmetry</p> Signup and view all the answers

    What should be done to the nozzle during cleaning?

    <p>Use a monarch brass wire brush to clean it</p> Signup and view all the answers

    What should be done to the burner assembly after dismantling?

    <p>Handle it carefully and clean it thoroughly</p> Signup and view all the answers

    Why should the refractory be inspected each time the boiler is opened up for cleaning?

    <p>To prolong its life</p> Signup and view all the answers

    What should be done to the fuel lines before removing the burner assembly?

    <p>Lock the manual stop valves closed</p> Signup and view all the answers

    What should be done to the burner nozzle after cleaning?

    <p>Polish it lightly with a round, sharpened toothpick</p> Signup and view all the answers

    HARD Why should leaks in steam and water connections be repaired as soon as they are noticed?

    <p>To prevent erosion of the sealing surfaces</p> Signup and view all the answers

    What is the purpose of flushing out a new boiler with a high-pressure hose?

    <p>To remove any debris or sediment</p> Signup and view all the answers

    Why should gland nuts be tightened only enough to prevent excessive leakage?

    <p>To prevent scoring of the shaft</p> Signup and view all the answers

    What should be inspected for scale formation and pitting?

    <p>Tubes and tube sheets</p> Signup and view all the answers

    Why should boiler operators watch for leaks in steam and water connections?

    <p>To prevent erosion of the sealing surfaces</p> Signup and view all the answers

    What should be done to prevent drying out of packing and scoring of the shaft in pumps with packing glands?

    <p>Allow a few drops of leakage per minute</p> Signup and view all the answers

    Why should confined space entry procedures be followed?

    <p>To prevent accidents and injuries</p> Signup and view all the answers

    What should be done to new boilers after the first three months of operation?

    <p>Flush out the boiler with a high-pressure hose</p> Signup and view all the answers

    Why is it necessary to remove impurities from the boiler during the annual shutdown and maintenance?

    <p>To prevent corrosion during extended non-operating periods</p> Signup and view all the answers

    What is the purpose of testing all safety limit controls during the annual shutdown and maintenance?

    <p>To identify and repair defective controls during the off-season</p> Signup and view all the answers

    Why is it important to apply a light coating of oil to the fireside surfaces of the boiler during extended non-operating periods?

    <p>To prevent corrosion of the boiler surfaces</p> Signup and view all the answers

    What should be done to the boiler drain cocks during the annual shutdown and maintenance?

    <p>They should be briefly opened one at a time to remove impurities</p> Signup and view all the answers

    Why should cast iron steam boilers be prepared for annual shutdown and maintenance differently than steel steam boilers?

    <p>Because they require wet layup or dry layup depending on the shutdown period</p> Signup and view all the answers

    What should be done to the boiler before placing it back in service after wet layup?

    <p>It should be drained to the normal operating water level</p> Signup and view all the answers

    Why should the firing circuit be disabled and locked out during the annual shutdown and maintenance?

    <p>To prevent accidental firing of the boiler</p> Signup and view all the answers

    What should be done to the boiler vent connector during the annual shutdown and maintenance?

    <p>It should be cleaned all the way to the chimney base tee</p> Signup and view all the answers

    Why should the boiler be shut down following the manufacturer's instructions?

    <p>To follow the manufacturer's specific instructions</p> Signup and view all the answers

    What should be done to the ductwork, breeching, piping, and pipe fittings during the annual shutdown and maintenance?

    <p>They should be cleaned and inspected</p> Signup and view all the answers

    What should be the primary focus of the boiler operator during regular operation?

    <p>Maintaining the proper fuel-air ratio for complete combustion</p> Signup and view all the answers

    What is a critical step to ensure the safety valve is free to operate when the boiler is under pressure?

    <p>Operate the safety valve try-lever</p> Signup and view all the answers

    Why is it important to drain the boiler after it cools, rather than when it is hot?

    <p>To prevent remaining sediment from baking on the metal surfaces, making it harder to remove</p> Signup and view all the answers

    What is the recommended procedure for repairing refractory cracks?

    <p>Using gunnable refractory materials that dry soft and pliable</p> Signup and view all the answers

    What is the primary reason for covering the door gaskets with graphite and oil or an anti-seize compound?

    <p>To make future opening easier</p> Signup and view all the answers

    What is the purpose of cleaning the boiler waterside heating surfaces with a high-pressure water hose?

    <p>To remove remaining sludge and sediment</p> Signup and view all the answers

    What should be done to the boiler if it is to be on standby, rather than being shut down for an extended period?

    <p>It should be laid-up wet, after firing it long enough to ensure the layup chemicals are circulated throughout the boiler</p> Signup and view all the answers

    What should be done to the burner assembly before reassembling it?

    <p>All of the above</p> Signup and view all the answers

    Why should the boiler waterside be dried thoroughly prior to inspection?

    <p>To prevent corrosion during extended non-operating periods</p> Signup and view all the answers

    Why should the burner nozzle be properly centered and extended the correct amount into the nozzle tube?

    <p>To maintain the correct spray angle</p> Signup and view all the answers

    What should be done to the burner tubes of boilers with atmospheric burners during the off-season?

    <p>They should be covered to protect them from dust</p> Signup and view all the answers

    What should be done to the fuel lines before removing the burner assembly?

    <p>Lock the fuel line manual stop valves closed</p> Signup and view all the answers

    Why should the pressure control piping be cleaned?

    <p>To prevent plugging of the pressure control pigtails</p> Signup and view all the answers

    What should be done to the refractory to prolong its life?

    <p>Regularly washing it with a diluted heat-resistant cement</p> Signup and view all the answers

    What should be done to the scanner tube during cleaning?

    <p>Running a cloth through it to keep it clean and shiny</p> Signup and view all the answers

    What should be done to the gauge glass connections if they are obstructed?

    <p>They should be cleaned out</p> Signup and view all the answers

    Why should the ductwork, breeching, piping, and pipe fittings be inspected for cracks, corrosion, and signs of leakage?

    <p>To prevent leaks in steam and water connections</p> Signup and view all the answers

    Why should the burner and fan motor be regularly lubricated?

    <p>To reduce wear and tear</p> Signup and view all the answers

    What should be done to the boiler after cleaning the fireside surfaces?

    <p>All of the above</p> Signup and view all the answers

    What should be done to the boiler if it is out of service for an extended period of time?

    <p>It should be left in dry layup</p> Signup and view all the answers

    Study Notes

    General Maintenance

    • Ensure site-specific and jurisdictional lockout and work procedure requirements are followed before performing maintenance activities.
    • Familiarize yourself with confined space rules, regulations, and procedures before entering a confined space.
    • Watch for leaks in steam and water connections, and repair them as soon as possible to prevent erosion and gauge glass failure.
    • Periodically check and adjust the tightness of packing glands, flange bolts, handhole and manhole yokes, and unions to prevent leaks.

    Washing Out the Boiler

    • New boilers should be shut down, drained, opened up, flushed out with a high-pressure hose, and inspected after the first three months of operation.
    • Repeat this procedure as often as conditions warrant to inspect tubes and tube sheets for scale formation and pitting.

    Cleaning the Firetubes

    • Open the front and rear doors of the reversing chambers, and brush the tubes to remove soot deposits.
    • Remove flame retarders and inspect tubes and tubesheets for scale formation and pitting.
    • Reinstall flame retarders after cleaning, and close the doors with graphite and oil or anti-seize compound to ensure easy opening.

    Lubrication

    • The burner and fan motor may have standard ball bearings or pre-lubricated sealed bearings that require lubrication at different frequencies.
    • Follow the manufacturer's recommendation for lubrication frequency and type of lubricant required.

    Refractory Maintenance

    • Inspect the refractory each time the boiler is opened up for cleaning, and washcoat it with a diluted heat-resistant cement to prolong its life.
    • Replace burned-out or broken refractory segments with the same kind of material, and consult a refractory contractor for further information.

    Burner Maintenance

    • Maintain the proper fuel-air ratio for complete combustion, and observe the burner flame regularly during operation.
    • Clean and inspect the burner periodically, following the procedure in the boiler manual.

    Heating Boiler Annual Maintenance – Hot Water Service

    • Conduct a complete check of the system at the end of the heating season, and ensure all repairs are done immediately.
    • Briefly open the boiler drain cocks to remove impurities, and test all safety limit controls.
    • Shut down the boiler following manufacturer instructions, and close and lock out all fuel valves.

    Cast Iron Sectional Heating Boiler Annual Maintenance – Steam Service

    • Prepare a cast iron steam boiler for annual shutdown and maintenance using the procedure for steel steam boiler maintenance.
    • Fill the boiler up to the base of the main steam outlet with treated water (wet layup) before placing it back in service.

    Power Boiler Annual Maintenance

    • Take hot water power boilers out of service and maintain them like hot water heating boilers.
    • Follow the manufacturer's specific instructions for maintenance, and perform tasks such as blowing sediment from the base of the boiler, testing safety limit controls, and cleaning the boiler fireside and waterside.

    General Maintenance

    • Ensure site-specific and jurisdictional lockout and work procedure requirements are followed before performing maintenance activities.
    • Familiarize yourself with confined space rules, regulations, and procedures before entering a confined space.
    • Watch for leaks in steam and water connections, and repair them as soon as possible to prevent erosion and gauge glass failure.
    • Periodically check and adjust the tightness of packing glands, flange bolts, handhole and manhole yokes, and unions to prevent leaks.

    Washing Out the Boiler

    • New boilers should be shut down, drained, opened up, flushed out with a high-pressure hose, and inspected after the first three months of operation.
    • Repeat this procedure as often as conditions warrant to inspect tubes and tube sheets for scale formation and pitting.

    Cleaning the Firetubes

    • Open the front and rear doors of the reversing chambers, and brush the tubes to remove soot deposits.
    • Remove flame retarders and inspect tubes and tubesheets for scale formation and pitting.
    • Reinstall flame retarders after cleaning, and close the doors with graphite and oil or anti-seize compound to ensure easy opening.

    Lubrication

    • The burner and fan motor may have standard ball bearings or pre-lubricated sealed bearings that require lubrication at different frequencies.
    • Follow the manufacturer's recommendation for lubrication frequency and type of lubricant required.

    Refractory Maintenance

    • Inspect the refractory each time the boiler is opened up for cleaning, and washcoat it with a diluted heat-resistant cement to prolong its life.
    • Replace burned-out or broken refractory segments with the same kind of material, and consult a refractory contractor for further information.

    Burner Maintenance

    • Maintain the proper fuel-air ratio for complete combustion, and observe the burner flame regularly during operation.
    • Clean and inspect the burner periodically, following the procedure in the boiler manual.

    Heating Boiler Annual Maintenance – Hot Water Service

    • Conduct a complete check of the system at the end of the heating season, and ensure all repairs are done immediately.
    • Briefly open the boiler drain cocks to remove impurities, and test all safety limit controls.
    • Shut down the boiler following manufacturer instructions, and close and lock out all fuel valves.

    Cast Iron Sectional Heating Boiler Annual Maintenance – Steam Service

    • Prepare a cast iron steam boiler for annual shutdown and maintenance using the procedure for steel steam boiler maintenance.
    • Fill the boiler up to the base of the main steam outlet with treated water (wet layup) before placing it back in service.

    Power Boiler Annual Maintenance

    • Take hot water power boilers out of service and maintain them like hot water heating boilers.
    • Follow the manufacturer's specific instructions for maintenance, and perform tasks such as blowing sediment from the base of the boiler, testing safety limit controls, and cleaning the boiler fireside and waterside.

    General Maintenance

    • Ensure site-specific and jurisdictional lockout and work procedure requirements are followed before performing maintenance activities.
    • Familiarize yourself with confined space rules, regulations, and procedures before entering a confined space.
    • Watch for leaks in steam and water connections, and repair them as soon as possible to prevent erosion and gauge glass failure.
    • Periodically check and adjust the tightness of packing glands, flange bolts, handhole and manhole yokes, and unions to prevent leaks.

    Washing Out the Boiler

    • New boilers should be shut down, drained, opened up, flushed out with a high-pressure hose, and inspected after the first three months of operation.
    • Repeat this procedure as often as conditions warrant to inspect tubes and tube sheets for scale formation and pitting.

    Cleaning the Firetubes

    • Open the front and rear doors of the reversing chambers, and brush the tubes to remove soot deposits.
    • Remove flame retarders and inspect tubes and tubesheets for scale formation and pitting.
    • Reinstall flame retarders after cleaning, and close the doors with graphite and oil or anti-seize compound to ensure easy opening.

    Lubrication

    • The burner and fan motor may have standard ball bearings or pre-lubricated sealed bearings that require lubrication at different frequencies.
    • Follow the manufacturer's recommendation for lubrication frequency and type of lubricant required.

    Refractory Maintenance

    • Inspect the refractory each time the boiler is opened up for cleaning, and washcoat it with a diluted heat-resistant cement to prolong its life.
    • Replace burned-out or broken refractory segments with the same kind of material, and consult a refractory contractor for further information.

    Burner Maintenance

    • Maintain the proper fuel-air ratio for complete combustion, and observe the burner flame regularly during operation.
    • Clean and inspect the burner periodically, following the procedure in the boiler manual.

    Heating Boiler Annual Maintenance – Hot Water Service

    • Conduct a complete check of the system at the end of the heating season, and ensure all repairs are done immediately.
    • Briefly open the boiler drain cocks to remove impurities, and test all safety limit controls.
    • Shut down the boiler following manufacturer instructions, and close and lock out all fuel valves.

    Cast Iron Sectional Heating Boiler Annual Maintenance – Steam Service

    • Prepare a cast iron steam boiler for annual shutdown and maintenance using the procedure for steel steam boiler maintenance.
    • Fill the boiler up to the base of the main steam outlet with treated water (wet layup) before placing it back in service.

    Power Boiler Annual Maintenance

    • Take hot water power boilers out of service and maintain them like hot water heating boilers.
    • Follow the manufacturer's specific instructions for maintenance, and perform tasks such as blowing sediment from the base of the boiler, testing safety limit controls, and cleaning the boiler fireside and waterside.

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    Description

    This quiz assesses knowledge of boiler maintenance procedures, including lockout and work procedures, confined space entry, and site-specific regulations. Ensure familiarity with confined space rules and procedures before entering a confined space.

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