Podcast
Questions and Answers
EASY What material are hot water heating boilers commonly made of?
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?
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?
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?
What should be checked for cracks, corrosion, and signs of leakage?
What should be done to the boiler at the end of the heating season?
What should be done to the boiler at the end of the heating season?
How should cast iron steam boilers be prepared for annual shutdown and maintenance?
How should cast iron steam boilers be prepared for annual shutdown and maintenance?
What should be done to the boiler before placing it back in service after wet layup?
What should be done to the boiler before placing it back in service after wet layup?
When should cast iron steam boilers be left empty (dry layup)?
When should cast iron steam boilers be left empty (dry layup)?
How should power boilers be maintained?
How should power boilers be maintained?
What should be done to the boiler while it is in operation and under pressure?
What should be done to the boiler while it is in operation and under pressure?
What is the first step in cleaning the tubes and tubesheets?
What is the first step in cleaning the tubes and tubesheets?
How often do standard ball bearings typically require lubrication?
How often do standard ball bearings typically require lubrication?
What should be done to refractory cracks?
What should be done to refractory cracks?
What is a good indication of a clean burner?
What is a good indication of a clean burner?
How often should gas burners be cleaned and inspected?
How often should gas burners be cleaned and inspected?
What should be used to remove carbon build-up from the nozzle?
What should be used to remove carbon build-up from the nozzle?
What should be done to the fuel lines before removing the burner assembly?
What should be done to the fuel lines before removing the burner assembly?
Why should the door gaskets be covered with graphite and oil or an anti-seize compound?
Why should the door gaskets be covered with graphite and oil or an anti-seize compound?
What should be done to the scanner tube during cleaning?
What should be done to the scanner tube during cleaning?
What should be done after reassembling the burner assembly?
What should be done after reassembling the burner assembly?
When should you operate the safety valve try-lever?
When should you operate the safety valve try-lever?
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?
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?
What should be done to the burner tubes of boilers with atmospheric burners during the off-season?
What should be done to the burner tubes of boilers with atmospheric burners during the off-season?
How should you clean the boiler fireside heating surfaces?
How should you clean the boiler fireside heating surfaces?
Why should you apply a light coating of oil to the fireside surfaces?
Why should you apply a light coating of oil to the fireside surfaces?
What should you do after draining the boiler?
What should you do after draining the boiler?
What should you do if hard scale is baked on the internal surfaces of the boiler?
What should you do if hard scale is baked on the internal surfaces of the boiler?
Why should you dry the boiler waterside thoroughly prior to inspection?
Why should you dry the boiler waterside thoroughly prior to inspection?
What should be done to power boilers in steam service if they are out of service for long periods of time?
What should be done to power boilers in steam service if they are out of service for long periods of time?
What should be done to condensate return piping?
What should be done to condensate return piping?
What should boiler operators watch for in steam and water connections?
What should boiler operators watch for in steam and water connections?
Why should leaks be repaired as soon as they are noticed?
Why should leaks be repaired as soon as they are noticed?
What is the recommended frequency for inspecting boiler feed pump or hot water circulating pump packing glands?
What is the recommended frequency for inspecting boiler feed pump or hot water circulating pump packing glands?
Why should gland nuts be tightened only enough to prevent excessive leakage?
Why should gland nuts be tightened only enough to prevent excessive leakage?
What should be done to new boilers after the first three months of operation?
What should be done to new boilers after the first three months of operation?
Why should the tightness of packing glands, flange bolts, handhole and manhole yokes, and unions be periodically checked and adjusted?
Why should the tightness of packing glands, flange bolts, handhole and manhole yokes, and unions be periodically checked and adjusted?
What should be inspected for scale formation and pitting?
What should be inspected for scale formation and pitting?
How should firetubes with soot coating be cleaned?
How should firetubes with soot coating be cleaned?
MEDIUM What should be done to new boilers after the first three months of operation?
MEDIUM What should be done to new boilers after the first three months of operation?
What should be done to prevent drying out of packing and scoring of the shaft in pumps with packing glands?
What should be done to prevent drying out of packing and scoring of the shaft in pumps with packing glands?
Why should boiler operators watch for leaks in steam and water connections?
Why should boiler operators watch for leaks in steam and water connections?
What should be inspected for scale formation and pitting?
What should be inspected for scale formation and pitting?
Why should leaks in gauge glass packing be repaired as soon as possible?
Why should leaks in gauge glass packing be repaired as soon as possible?
How often should the tightness of packing glands, flange bolts, handhole and manhole yokes, and unions be checked and adjusted?
How often should the tightness of packing glands, flange bolts, handhole and manhole yokes, and unions be checked and adjusted?
What should be done to prevent leaks in steam and water connections?
What should be done to prevent leaks in steam and water connections?
Why should confined space entry procedures be followed?
Why should confined space entry procedures be followed?
What is the minimum steam pressure required to open power boiler safety valves with the try-lever?
What is the minimum steam pressure required to open power boiler safety valves with the try-lever?
What should be done to the boiler fireside heating surfaces during extended non-operating periods?
What should be done to the boiler fireside heating surfaces during extended non-operating periods?
Why should the boiler waterside be dried thoroughly prior to inspection?
Why should the boiler waterside be dried thoroughly prior to inspection?
What should be done to the burner tubes of boilers with atmospheric burners during the off-season?
What should be done to the burner tubes of boilers with atmospheric burners during the off-season?
What should be done to the boiler after it cools down?
What should be done to the boiler after it cools down?
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?
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?
What should be done to the condensate return piping?
What should be done to the condensate return piping?
What should be done to power boilers in steam service if they are out of service for long periods of time?
What should be done to power boilers in steam service if they are out of service for long periods of time?
What should be done to the gauge glass connections?
What should be done to the gauge glass connections?
Why should the low water cutoff float and switches be examined?
Why should the low water cutoff float and switches be examined?
What is the recommended procedure for removing impurities from a hot water heating boiler?
What is the recommended procedure for removing impurities from a hot water heating boiler?
Why is it important to clean the vent connector and breeching during annual maintenance?
Why is it important to clean the vent connector and breeching during annual maintenance?
What should be done to the fuel valves during the off-season?
What should be done to the fuel valves during the off-season?
What is the recommended procedure for preparing a cast iron steam boiler for annual shutdown and maintenance?
What is the recommended procedure for preparing a cast iron steam boiler for annual shutdown and maintenance?
Why should the firing circuit be disabled and locked out during the off-season?
Why should the firing circuit be disabled and locked out during the off-season?
What should be done to the boiler's ductwork, breeching, piping, and pipe fittings during annual maintenance?
What should be done to the boiler's ductwork, breeching, piping, and pipe fittings during annual maintenance?
What should be done to the low water cut-off float assembly during annual maintenance?
What should be done to the low water cut-off float assembly during annual maintenance?
Why is it important to apply a light coating of oil to the fireside surfaces during extended non-operating periods?
Why is it important to apply a light coating of oil to the fireside surfaces during extended non-operating periods?
What is the recommended procedure for maintaining power boilers in steam service?
What is the recommended procedure for maintaining power boilers in steam service?
Why is it important to follow the manufacturer's recommendations for boiler maintenance?
Why is it important to follow the manufacturer's recommendations for boiler maintenance?
What should be done before cleaning the tubes and tubesheets?
What should be done before cleaning the tubes and tubesheets?
What is the purpose of covering the door gaskets with graphite and oil or an anti-seize compound?
What is the purpose of covering the door gaskets with graphite and oil or an anti-seize compound?
How often should sealed bearings typically be lubricated?
How often should sealed bearings typically be lubricated?
What should be used to repair refractory cracks?
What should be used to repair refractory cracks?
What should be observed regularly during boiler operation to indicate a clean burner?
What should be observed regularly during boiler operation to indicate a clean burner?
What should be done to the nozzle during cleaning?
What should be done to the nozzle during cleaning?
What should be done to the burner assembly after dismantling?
What should be done to the burner assembly after dismantling?
Why should the refractory be inspected each time the boiler is opened up for cleaning?
Why should the refractory be inspected each time the boiler is opened up for cleaning?
What should be done to the fuel lines before removing the burner assembly?
What should be done to the fuel lines before removing the burner assembly?
What should be done to the burner nozzle after cleaning?
What should be done to the burner nozzle after cleaning?
HARD Why should leaks in steam and water connections be repaired as soon as they are noticed?
HARD Why should leaks in steam and water connections be repaired as soon as they are noticed?
What is the purpose of flushing out a new boiler with a high-pressure hose?
What is the purpose of flushing out a new boiler with a high-pressure hose?
Why should gland nuts be tightened only enough to prevent excessive leakage?
Why should gland nuts be tightened only enough to prevent excessive leakage?
What should be inspected for scale formation and pitting?
What should be inspected for scale formation and pitting?
Why should boiler operators watch for leaks in steam and water connections?
Why should boiler operators watch for leaks in steam and water connections?
What should be done to prevent drying out of packing and scoring of the shaft in pumps with packing glands?
What should be done to prevent drying out of packing and scoring of the shaft in pumps with packing glands?
Why should confined space entry procedures be followed?
Why should confined space entry procedures be followed?
What should be done to new boilers after the first three months of operation?
What should be done to new boilers after the first three months of operation?
Why is it necessary to remove impurities from the boiler during the annual shutdown and maintenance?
Why is it necessary to remove impurities from the boiler during the annual shutdown and maintenance?
What is the purpose of testing all safety limit controls during the annual shutdown and maintenance?
What is the purpose of testing all safety limit controls during the annual shutdown and maintenance?
Why is it important to apply a light coating of oil to the fireside surfaces of the boiler during extended non-operating periods?
Why is it important to apply a light coating of oil to the fireside surfaces of the boiler during extended non-operating periods?
What should be done to the boiler drain cocks during the annual shutdown and maintenance?
What should be done to the boiler drain cocks during the annual shutdown and maintenance?
Why should cast iron steam boilers be prepared for annual shutdown and maintenance differently than steel steam boilers?
Why should cast iron steam boilers be prepared for annual shutdown and maintenance differently than steel steam boilers?
What should be done to the boiler before placing it back in service after wet layup?
What should be done to the boiler before placing it back in service after wet layup?
Why should the firing circuit be disabled and locked out during the annual shutdown and maintenance?
Why should the firing circuit be disabled and locked out during the annual shutdown and maintenance?
What should be done to the boiler vent connector during the annual shutdown and maintenance?
What should be done to the boiler vent connector during the annual shutdown and maintenance?
Why should the boiler be shut down following the manufacturer's instructions?
Why should the boiler be shut down following the manufacturer's instructions?
What should be done to the ductwork, breeching, piping, and pipe fittings during the annual shutdown and maintenance?
What should be done to the ductwork, breeching, piping, and pipe fittings during the annual shutdown and maintenance?
What should be the primary focus of the boiler operator during regular operation?
What should be the primary focus of the boiler operator during regular operation?
What is a critical step to ensure the safety valve is free to operate when the boiler is under pressure?
What is a critical step to ensure the safety valve is free to operate when the boiler is under pressure?
Why is it important to drain the boiler after it cools, rather than when it is hot?
Why is it important to drain the boiler after it cools, rather than when it is hot?
What is the recommended procedure for repairing refractory cracks?
What is the recommended procedure for repairing refractory cracks?
What is the primary reason for covering the door gaskets with graphite and oil or an anti-seize compound?
What is the primary reason for covering the door gaskets with graphite and oil or an anti-seize compound?
What is the purpose of cleaning the boiler waterside heating surfaces with a high-pressure water hose?
What is the purpose of cleaning the boiler waterside heating surfaces with a high-pressure water hose?
What should be done to the boiler if it is to be on standby, rather than being shut down for an extended period?
What should be done to the boiler if it is to be on standby, rather than being shut down for an extended period?
What should be done to the burner assembly before reassembling it?
What should be done to the burner assembly before reassembling it?
Why should the boiler waterside be dried thoroughly prior to inspection?
Why should the boiler waterside be dried thoroughly prior to inspection?
Why should the burner nozzle be properly centered and extended the correct amount into the nozzle tube?
Why should the burner nozzle be properly centered and extended the correct amount into the nozzle tube?
What should be done to the burner tubes of boilers with atmospheric burners during the off-season?
What should be done to the burner tubes of boilers with atmospheric burners during the off-season?
What should be done to the fuel lines before removing the burner assembly?
What should be done to the fuel lines before removing the burner assembly?
Why should the pressure control piping be cleaned?
Why should the pressure control piping be cleaned?
What should be done to the refractory to prolong its life?
What should be done to the refractory to prolong its life?
What should be done to the scanner tube during cleaning?
What should be done to the scanner tube during cleaning?
What should be done to the gauge glass connections if they are obstructed?
What should be done to the gauge glass connections if they are obstructed?
Why should the ductwork, breeching, piping, and pipe fittings be inspected for cracks, corrosion, and signs of leakage?
Why should the ductwork, breeching, piping, and pipe fittings be inspected for cracks, corrosion, and signs of leakage?
Why should the burner and fan motor be regularly lubricated?
Why should the burner and fan motor be regularly lubricated?
What should be done to the boiler after cleaning the fireside surfaces?
What should be done to the boiler after cleaning the fireside surfaces?
What should be done to the boiler if it is out of service for an extended period of time?
What should be done to the boiler if it is out of service for an extended period of time?
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.
