78 Questions
EASY What is the purpose of checking the fuel train line of the steam boiler?
To inspect for fuel leaks
Why do safety valves in steam heating boilers often fail to open at their set pressure?
Due to deposit buildup
What is the recommended operating pressure for steam heating boilers?
70 kPa (10 psi)
Why is a high steam pressure cut-off required in power boilers?
To prevent the boiler pressure from exceeding the maximum allowable working pressure
What should be observed after firing up a power boiler?
The steam pressure reaches a plateau
What can rising stack temperatures, at a given firing rate, indicate?
The heat transfer surfaces are becoming dirty
What is the purpose of recording the stack temperature?
To identify dirty heat transfer surfaces
What should be recorded along with the stack temperature?
The firing rate or boiler load
Why should the boiler operating parameters be inspected after it has been successfully fired?
To verify the boiler's performance is within expected ranges
What should be checked in a circulating pump with a stuffing box?
The proper amount of leakage
What should be the color of a natural gas flame?
Blue with orange at the tip
What should be done during a walk down of the fuel train?
Confirm there are no fuel leaks
Why is high pressure a common unsafe condition in hot water boilers?
Due to the failure of the safety relief valve to open at the set pressure
What should be done to the circulating pump to ensure quiet operation?
Ensure the pump has adequate flow of clean water to its seals
What should be checked to ensure the fuel flow is sufficient to meet the load demand of the boilers?
The fuel oil pump suction and discharge pressures
What should be the characteristic of the boiler's flame?
Turbulent and symmetrical
What is the recommended pressure difference between the normal boiler operating pressure and the safety relief valve setting?
25% or 69 kPa (10 psi)
What should the movable hand on the tridicator gauge indicate?
The actual system pressure is greater than the full system pressure
What is the maximum operating temperature of the boiler water in hot water heating systems?
120°C
Why is it important to maintain water at a safe level in a boiler?
To prevent overheating
What should be checked during a post-startup inspection for a steam boiler?
The water level controls, indicators, and recorders
How often should the boiler feed pumps be alternated?
Monthly
What should the color of a typical natural gas flame be?
Blue with orange at the tip
What should be done when the gate is open on the flame observation port?
Open the cooling air flow
What should be monitored and recorded along with the stack temperature?
Boiler load or firing rate
What should be checked regularly in hot water systems?
Both the boiler water temperature and expansion tank pressure
MEDIUM During the fuel train walk down, what should be confirmed about the fuel pumps?
They are operating within prescribed ranges
Why should the operating pressure of steam heating boilers be set to 35 kPa (5 psi) less than the safety valve setting?
To prevent weeping and protect the safety valve
What is the purpose of the high steam pressure cut-off in power boilers?
To prevent the boiler pressure from exceeding the boiler’s maximum allowable working pressure
Why is it important to record the stack temperature?
To determine when waterside or fireside surfaces require cleaning
What should be monitored and recorded along with the stack temperature?
Boiler load or firing rate
What happens when the safety valve blows in a power boiler?
The safety valve reseats before the high-pressure cut-off permits recycling of the boiler
What is the purpose of checking the pressure gauges downstream of the regulators and at the burner?
To evaluate whether the burner is operating properly
Why is a differential pressure required between the normal boiler operating pressure and the safety valve setting?
To help ensure that the safety valve will seat tightly after popping
What is the purpose of checking the circulating pump's discharge pressure?
To ensure the pump is operating within the expected range
What should be checked during the inspection of the boiler's fuel train?
The fuel oil pump suction and discharge pressures
What is the characteristic of a typical natural gas flame?
Blue with orange at the tip
Why is high pressure a common unsafe condition in hot water boilers?
Due to the failure of the safety relief valve to open at the set pressure
What should be checked in a circulating pump with mechanical seals?
The signs of leakage from the mechanical seals
What should be done to ensure the circulating pump operates quietly?
Ensure the pump has adequate flow of clean water to its seals
What should be checked to ensure the fuel flow is sufficient to meet the load demand of the boilers?
The fuel oil pump suction and discharge pressures
What should be the characteristic of the boiler's flame?
Turbulent and symmetrical
What is the likely cause of deposit buildup between the disk and seat of the valve in a boiler?
Valve leaking or weeping
What is the recommended pressure difference between the normal boiler operating pressure and the safety relief valve setting?
25% or 69 kPa
What does a rising stack temperature at a given firing rate indicate?
The heat transfer surfaces are becoming dirty
What should be the minimum reading of the movable hand on the tridicator gauge?
1.2m (11.8 kPa) greater than the stationary hand
What is the maximum operating temperature of the boiler water in hot water heating systems?
120°C
What should be checked regularly in hot water systems to prevent the safety valve from opening?
Expansion tank pressure
What should be maintained within range during steam boiler operation?
Water level
What should be visually checked during boiler operation?
Boiler flame
What should be done to the boiler feed pumps periodically?
Alternate the pumps
What should be checked to ensure the heating needs of the system are being met?
Water temperature
HARD What should be monitored on a regular basis to ensure the boiler operates within the expected range?
Pump discharge pressure, suction pressure, and differential pressure
What should be checked on the fuel train line of the hot water boiler?
Fuel leaks, pressure regulators, and burner operation
What is a typical characteristic of a well-functioning circulating pump?
Quiet operation and minimal vibration
Why is high pressure a common unsafe condition in hot water boilers?
Due to the failure of the safety relief valve to open at the set pressure
What should be checked on a circulating pump with a stuffing box?
Seal condition, packing condition, and lubrication
What should be confirmed during a walk-down of the fuel train?
Fuel leaks, proper valve operation, and proper burner operation
What should be monitored to ensure the fuel flow is sufficient to meet the load demand of the boilers?
Fuel pump flow rate, fuel pressure, and burner operation
What should be checked regularly in hot water systems to prevent the safety valve from opening?
Circulating pump operation, fuel flow rate, and boiler pressure
What is the primary purpose of recording burner pressure and firing rate?
To evaluate whether the burner is operating properly
What is the consequence of a rising stack temperature at a given firing rate?
The heat transfer surfaces are becoming dirty
What is the recommended differential pressure between the normal boiler operating pressure and the safety valve setting in steam heating boilers?
35 kPa (5 psi)
What is the purpose of the high steam pressure cut-off in power boilers?
To prevent the boiler pressure from exceeding the maximum allowable working pressure
What should be confirmed during the fuel train walk down?
That fuel oil pump suction and discharge pressures are operating within prescribed ranges
What is the recommended operating pressure for steam heating boilers?
35 kPa (5 psi)
Why is a differential pressure required between the normal boiler operating pressure and the safety valve setting?
To help ensure the safety valve will seat tightly after popping
What should be monitored and recorded along with the stack temperature?
Boiler load or firing rate
What is the primary reason for monitoring and recording the stack temperature during boiler operation?
To detect potential heat transfer surface fouling
What is the consequence of a failed expansion tank bladder in a hot water system?
There will be no room for expansion as the water is heated, leading to the safety valve opening
What is the significance of maintaining the correct water level in a steam boiler?
It prevents the boiler from overheating and endangering the boiler
What is the purpose of periodically alternating the boiler feed pumps?
To ensure equal wear and tear on the pumps
What is the characteristic of a light fuel oil flame in a boiler?
It is bright yellow with orange tips
What should be checked during a post-startup inspection for a steam boiler?
The boiler feedwater control valve and water level
What is the recommended minimum difference between the normal boiler operating pressure and the safety relief valve setting?
69 kPa (10 psi)
What is the consequence of a high boiler operating pressure in hot water boilers?
It can lead to corrosion and reduced system efficiency
What should be checked regularly in hot water systems to prevent the safety valve from opening?
The expansion tank pressure and bladder condition
What is the purpose of the manually operated gate on the flame observation port?
To protect the observation glass from excessive heat
Study Notes
Boiler Inspection and Operation
- After firing, warm-up, and placing the boiler online, inspect boiler operating parameters, including routine instrument checks, heating system checks, and auxiliary system checks.
Circulating Pump
- Check circulating pumps regularly for proper operation.
- Check stuffing boxes for proper leakage and mechanical seals for no signs of leakage.
- Ensure adequate flow of clean water to pump seals for cooling, sealing, and lubrication.
- Monitor pump discharge pressure, suction pressure, and differential pressure to ensure operation within expected range.
Flame
- Visually check boiler flame to ensure complete combustion.
- Typical natural gas flame is blue with orange at the tip, while light fuel oil flame is bright yellow with orange tips.
- Flames should not have black tips, be turbulent and symmetrical, and not impinge on any refractory or metal surface.
Fuel Train
- Periodically walk down the fuel train line and check for fuel leaks (fuel oil or natural gas).
- Check pressure gauges on fuel supply downstream of regulators and at the burner.
- Confirm fuel oil pump suction and discharge pressures are operating within prescribed ranges, and fuel pumps are not excessively noisy or vibrational.
Operating Pressure
- High pressure is a common unsafe condition found in hot water boilers.
- Normal boiler operating pressure should be 25% or 69 kPa (10 psi) less than the safety relief valve setting.
- Monitor system pressure to ensure it reaches the desired set point and does not increase beyond that point.
Stack Temperature
- Monitor and record stack temperature once the boiler has completely warmed up and is at normal operating pressure and temperature.
- Record boiler load or firing rate with stack temperature reading.
- Rising stack temperatures at a given firing rate indicate heat transfer surfaces are becoming dirty.
Water Temperature
- Maximum operating temperature of boiler water should not exceed 120°C.
- Monitor water temperature to ensure heating needs are being met and boiler operating controls are functioning properly.
Expansion Tank
- Check expansion tank pressure regularly.
- Pressure in the system may vary, but in most systems, boiler pressure should not go below 80 kPa or above 140 kPa.
Post Startup Inspection for Steam Boiler
Water Level
- Maintain water at a safe level in the boiler.
- Check water level controls, indicators, and recorders, and ensure they agree with one another.
- Check that the water level is being maintained within range in the boiler.
Feedwater Pumps
- Confirm feedwater pump operation by checking suction and discharge pressure, noise, vibration, and flow rate.
- Inspect shaft seals for leakage.
- Ensure pump and motor bearing lubrication and temperature are within range.
Flame (Steam Boiler)
- Visually check boiler flame to ensure complete combustion.
- Flames should not have black tips, be turbulent and symmetrical, and not impinge on any surface.
Fuel Train (Steam Boiler)
- Periodically walk down the fuel train line and check for fuel leaks (fuel oil or natural gas).
- Check pressure gauges on fuel supply, downstream of regulators, and at the burner.
- Confirm fuel oil pump suction and discharge pressures are operating within prescribed ranges, and fuel pumps are not excessively noisy or vibrational.
Operating Pressure (Steam Boiler)
- Commonly, steam heating boilers are found unsafe due to safety valves incapable of opening at their set pressure.
- Normal steam heating boiler operating pressure should be 35 kPa (5 psi) less than the safety valve setting.
- Power boilers must have a high steam pressure cut-off to prevent the boiler pressure from exceeding the boiler's maximum allowable working pressure.
Boiler Inspection and Operation
- After firing, warm-up, and placing the boiler online, inspect boiler operating parameters, including routine instrument checks, heating system checks, and auxiliary system checks.
Circulating Pump
- Check circulating pumps regularly for proper operation.
- Check stuffing boxes for proper leakage and mechanical seals for no signs of leakage.
- Ensure adequate flow of clean water to pump seals for cooling, sealing, and lubrication.
- Monitor pump discharge pressure, suction pressure, and differential pressure to ensure operation within expected range.
Flame
- Visually check boiler flame to ensure complete combustion.
- Typical natural gas flame is blue with orange at the tip, while light fuel oil flame is bright yellow with orange tips.
- Flames should not have black tips, be turbulent and symmetrical, and not impinge on any refractory or metal surface.
Fuel Train
- Periodically walk down the fuel train line and check for fuel leaks (fuel oil or natural gas).
- Check pressure gauges on fuel supply downstream of regulators and at the burner.
- Confirm fuel oil pump suction and discharge pressures are operating within prescribed ranges, and fuel pumps are not excessively noisy or vibrational.
Operating Pressure
- High pressure is a common unsafe condition found in hot water boilers.
- Normal boiler operating pressure should be 25% or 69 kPa (10 psi) less than the safety relief valve setting.
- Monitor system pressure to ensure it reaches the desired set point and does not increase beyond that point.
Stack Temperature
- Monitor and record stack temperature once the boiler has completely warmed up and is at normal operating pressure and temperature.
- Record boiler load or firing rate with stack temperature reading.
- Rising stack temperatures at a given firing rate indicate heat transfer surfaces are becoming dirty.
Water Temperature
- Maximum operating temperature of boiler water should not exceed 120°C.
- Monitor water temperature to ensure heating needs are being met and boiler operating controls are functioning properly.
Expansion Tank
- Check expansion tank pressure regularly.
- Pressure in the system may vary, but in most systems, boiler pressure should not go below 80 kPa or above 140 kPa.
Post Startup Inspection for Steam Boiler
Water Level
- Maintain water at a safe level in the boiler.
- Check water level controls, indicators, and recorders, and ensure they agree with one another.
- Check that the water level is being maintained within range in the boiler.
Feedwater Pumps
- Confirm feedwater pump operation by checking suction and discharge pressure, noise, vibration, and flow rate.
- Inspect shaft seals for leakage.
- Ensure pump and motor bearing lubrication and temperature are within range.
Flame (Steam Boiler)
- Visually check boiler flame to ensure complete combustion.
- Flames should not have black tips, be turbulent and symmetrical, and not impinge on any surface.
Fuel Train (Steam Boiler)
- Periodically walk down the fuel train line and check for fuel leaks (fuel oil or natural gas).
- Check pressure gauges on fuel supply, downstream of regulators, and at the burner.
- Confirm fuel oil pump suction and discharge pressures are operating within prescribed ranges, and fuel pumps are not excessively noisy or vibrational.
Operating Pressure (Steam Boiler)
- Commonly, steam heating boilers are found unsafe due to safety valves incapable of opening at their set pressure.
- Normal steam heating boiler operating pressure should be 35 kPa (5 psi) less than the safety valve setting.
- Power boilers must have a high steam pressure cut-off to prevent the boiler pressure from exceeding the boiler's maximum allowable working pressure.
Boiler Inspection and Operation
- After firing, warm-up, and placing the boiler online, inspect boiler operating parameters, including routine instrument checks, heating system checks, and auxiliary system checks.
Circulating Pump
- Check circulating pumps regularly for proper operation.
- Check stuffing boxes for proper leakage and mechanical seals for no signs of leakage.
- Ensure adequate flow of clean water to pump seals for cooling, sealing, and lubrication.
- Monitor pump discharge pressure, suction pressure, and differential pressure to ensure operation within expected range.
Flame
- Visually check boiler flame to ensure complete combustion.
- Typical natural gas flame is blue with orange at the tip, while light fuel oil flame is bright yellow with orange tips.
- Flames should not have black tips, be turbulent and symmetrical, and not impinge on any refractory or metal surface.
Fuel Train
- Periodically walk down the fuel train line and check for fuel leaks (fuel oil or natural gas).
- Check pressure gauges on fuel supply downstream of regulators and at the burner.
- Confirm fuel oil pump suction and discharge pressures are operating within prescribed ranges, and fuel pumps are not excessively noisy or vibrational.
Operating Pressure
- High pressure is a common unsafe condition found in hot water boilers.
- Normal boiler operating pressure should be 25% or 69 kPa (10 psi) less than the safety relief valve setting.
- Monitor system pressure to ensure it reaches the desired set point and does not increase beyond that point.
Stack Temperature
- Monitor and record stack temperature once the boiler has completely warmed up and is at normal operating pressure and temperature.
- Record boiler load or firing rate with stack temperature reading.
- Rising stack temperatures at a given firing rate indicate heat transfer surfaces are becoming dirty.
Water Temperature
- Maximum operating temperature of boiler water should not exceed 120°C.
- Monitor water temperature to ensure heating needs are being met and boiler operating controls are functioning properly.
Expansion Tank
- Check expansion tank pressure regularly.
- Pressure in the system may vary, but in most systems, boiler pressure should not go below 80 kPa or above 140 kPa.
Post Startup Inspection for Steam Boiler
Water Level
- Maintain water at a safe level in the boiler.
- Check water level controls, indicators, and recorders, and ensure they agree with one another.
- Check that the water level is being maintained within range in the boiler.
Feedwater Pumps
- Confirm feedwater pump operation by checking suction and discharge pressure, noise, vibration, and flow rate.
- Inspect shaft seals for leakage.
- Ensure pump and motor bearing lubrication and temperature are within range.
Flame (Steam Boiler)
- Visually check boiler flame to ensure complete combustion.
- Flames should not have black tips, be turbulent and symmetrical, and not impinge on any surface.
Fuel Train (Steam Boiler)
- Periodically walk down the fuel train line and check for fuel leaks (fuel oil or natural gas).
- Check pressure gauges on fuel supply, downstream of regulators, and at the burner.
- Confirm fuel oil pump suction and discharge pressures are operating within prescribed ranges, and fuel pumps are not excessively noisy or vibrational.
Operating Pressure (Steam Boiler)
- Commonly, steam heating boilers are found unsafe due to safety valves incapable of opening at their set pressure.
- Normal steam heating boiler operating pressure should be 35 kPa (5 psi) less than the safety valve setting.
- Power boilers must have a high steam pressure cut-off to prevent the boiler pressure from exceeding the boiler's maximum allowable working pressure.
This quiz covers the inspection of boiler operating parameters, including routine instrument checks, heating system checks, and auxiliary system checks. It also focuses on the proper operation of circulating pumps in hot water systems.
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