176 Questions
What is the primary purpose of having a handover discussion with the previous shift members?
To read and clarify the log book and be aware of the state of the power plant
What should engineers returning to shift after a set of days off do regarding the log book?
Read the log book as far back as the last time they took charge of the plant
What is commonly referred to as doing 'rounds'?
Becoming familiar with the operating condition of all plant equipment
How often may critical equipment be checked during a shift?
More often than less critical equipment
What is the purpose of reviewing log sheets during a shift handover?
To ensure a smooth transition between shifts
What determines the frequency of operator rounds?
All of the above
What is the primary purpose of conducting rounds in a plant?
To assess the operating condition of the plant using multiple senses
What is the typical frequency of checks in a comprehensive set of rounds?
One to two hours
Who typically performs the boiler plant rounds?
The shift engineer
What is the recommended action if the boiler water level is not at set point?
Blow down the water column and gauge glass
What is the purpose of checking the boiler feed pumps?
To check for vibration, unusual noise, leaks, and discharge pressure
What is the indication of rusty coloured condensate in the condensate receiver?
Corrosion in the condensate return system
What is the purpose of manually activating the condensate tank float switch?
To start the pump
What is the typical operating pressure range of a deaerator?
Between 70 and 400 kPa
What is the indication of a water temperature below the saturation pressure of the steam in a deaerator?
The deaerator vent is obstructed
Why is it important to check the standby pump in a steam boiler plant?
To ensure it is ready to be put in service if the primary pump fails
What is the approximate absolute pressure corresponding to 99 kPag?
200 kPa
What is the ideal temperature of deaerated water at 99 kPag?
120°C
What is the primary purpose of checking the brine tank in a water treatment plant?
To monitor the level of undissolved salt
What is the typical condition of the expansion tank in a hot water boiler plant?
About half way full
What should the heating loop temperature be in a hot water boiler plant?
At the set point
Why is it essential to check the safety valves in a hot water boiler plant?
To ensure they are functioning properly
What is the primary cause of excessive draft loss in a boiler?
Fireside obstruction
What is the ideal condition of the flame in a boiler plant?
Bright and free of soot
Why is it necessary to check the flue gas temperature in a boiler plant?
To identify potential problems with the heat exchanger
What is the primary purpose of performing water tests in a water treatment plant?
To monitor the quality of the water
What is the purpose of blowing down the water column and gauge glass every shift?
To remove any sediment that may collect
What can happen if the gauge glass is blown down frequently on large boilers?
The life of the mica will be shortened and increase maintenance costs
What should be done if the gauge glass becomes obscured by internal corrosion or deposits?
It should be renewed
What is the purpose of monitoring the feedwater level controllers regularly?
To ensure the boiler water level is at set point
What is an indication of a failed steam trap?
Constant flow of steam from the test valve
What is an indirect method of checking a steam trap?
Using a hand-held infrared thermometer
What is the primary purpose of ensuring unobstructed air openings into the boiler room?
To provide fresh air for ventilation and combustion
What is the role of the assistant shift engineer in plant rounds?
To conduct the plant rounds
What is the primary function of the air compressor in the power plant?
To provide compressed air for automatic valves
Why is it essential to ensure the air inlet of the air compressor is free from obstruction?
To ensure adequate compressed air pressure
What is the purpose of checking the dew point of the compressed air?
To ensure the air is dry enough for automatic valves
Why is it crucial to maintain the correct coolant flow in the air compressor?
To reduce the risk of overheating
What is the purpose of the block heater in the standby generator?
To warm the engine for starting
Why is it essential to clean up spills immediately in the boiler room?
To promote a safe work environment
What is the purpose of checking the electrolyte levels in the standby generator's batteries?
To maintain the correct electrolyte levels for engine starting
Why is it important to segregate unidentified materials in the boiler room?
To ensure safe disposal of hazardous materials
What is the correct procedure to follow when a water column blowdown is completed at the beginning of every shift?
Check that the steam side and waterside isolating valves are fully open.
Why is it important to check for leaks that develop during maintenance?
To prevent hazards that do not normally exist during maintenance.
What is the purpose of recording areas that need replacement lamps?
To make plant areas with burned out luminaires safe.
What should be done with open floor grates that were removed to facilitate maintenance?
They should be taped off with caution tape.
What is the correct procedure to follow when a gauge glass is connected to a water column?
Close the gauge steam and water valves to isolate the gauge.
What is the purpose of blowing down the water column?
To clear the passages on the water column and gauge glass.
In what situations are isolation valves in the steam and water piping between the water column and the boiler used?
In high-pressure steam boilers.
What should be done after the water column blowdown is completed?
The water column should be placed back in operation.
Why is it important to observe changing conditions during maintenance?
To identify hazards that do not normally exist.
What should be done with plant areas that are unsafe due to burned out luminaires?
They should be signposted warning of the hazards.
What is the primary purpose of reading the log book prior to the start of a shift?
To become aware of the state of the power plant
How often may operator rounds be performed in a shift?
Once, twice, or three times per shift
What is the purpose of reviewing log sheets during a shift handover?
To discuss the activities of the previous shift
Who should read the log book as far back as the last time they took charge of the plant?
Engineers returning to shift after a set of days off
What is the purpose of the handover discussion with the previous shift members?
To discuss the activities of the previous shift
What determines the frequency of operator rounds?
All of the above
What is the primary purpose of assessing the operating condition of the plant using all the senses during rounds?
To identify potential safety hazards
Which of the following is an indication of corrosion in the condensate return system?
Rusty coloured condensate
What is the purpose of adjusting the pump packing in boiler feed pumps?
To prevent shaft leakage
What is the indication of a defective make-up water softening equipment in the condensate receiver?
Hard condensate
What is the purpose of ensuring the standby pump is ready to be put in service in a steam boiler plant?
To provide redundancy in case of primary pump failure
What is the purpose of checking the deaerator vent valve during boiler plant rounds?
To vent non-condensable gases
What is the indication of a failed condensate return tank pump?
Water flowing from the condensate tank vent
What is the purpose of checking the boiler pressure during boiler plant rounds?
To ensure the boiler pressure is at or near set point
What is the purpose of checking the condensate receiver level during boiler plant rounds?
To ensure the condensate receiver level is indicated on the gauge glasses
What is the purpose of checking the steam pressure during boiler plant rounds?
To ensure the main steam header pressure is normal
What is the primary reason for checking the brine tank level in a sodium zeolite softener?
To check for undissolved lumps of salt
What is the indication of a temperature reading of 105°C on a deaerator operating at 100 kPag?
The temperature is not acceptable
Why is it important to check the operation of equipment in the water treatment area of the power plant?
To check for leaks and vibration
What should be done if the safety valves on the boilers or the heating system are lifting?
Check the level of water in the expansion tank
What is the purpose of performing a water test in a water treatment plant?
To ensure the regeneration completed successfully
What is the indication of a high temperature reading on a boiler?
The high temperature cut-off set point is reached
What is the purpose of checking the flow totalizer in an ion-exchange softener?
To determine when a regeneration is necessary
What is the primary reason for checking the heating loop temperature in a hot water boiler plant?
To ensure the heating loop temperature is at the required set point
What is the indication of a low temperature reading on a deaerator operating at 100 kPag?
The temperature is not acceptable
What is the primary purpose of checking the pumps in a hot water boiler plant?
To check for leaks and unusual noise
What is the primary reason for assessing lighting in a power plant?
To identify areas that need replacement lamps and record them
What is the purpose of opening the water column drain valve during a water column blowdown?
To prove the steam connection is clear
What is the correct procedure for checking the water level in a boiler?
Ensure the water column is not obstructed, then check the water level
What is the purpose of taping off or signposting areas with open floor grates that were removed to facilitate maintenance?
To prevent tripping hazards
Why is it important to observe changing conditions during maintenance?
To prevent hazards that do not normally exist
What is the main purpose of blowing down the water column and gauge glass on smaller high-pressure boilers?
To remove sediment that may collect
What is the purpose of the detailed procedures for checks during plant rounds?
To provide specific instructions for performing checks during plant rounds
What is the primary purpose of ensuring unobstructed air openings into the boiler room?
To provide a clear path for combustion air
What is the indication of a failed steam trap, as observed during a direct method of checking?
Constant flow of steam from the test valve
Why is it important to report areas that need replacement lamps to the shift engineer?
To facilitate maintenance and ensure safety
What is the purpose of checking the water column connections during a water column blowdown?
To prove the steam and water connections are clear
Why is it important to monitor the feedwater level controllers regularly?
To ensure the boiler water level is at set point
What is the role of the air compressor in the power plant?
To provide dry compressed air for automatic valves and damper positioners
What is the recommended action to take when the intake louvres on the exterior of the building are found to be blocked?
Clean the intake louvres to ensure proper airflow
What is the recommended procedure to test the operation of the feedwater control valve?
Close the isolation valve downstream of the feedwater valve
What is the purpose of locking isolation valves in the open position in high-pressure steam boilers?
To ensure the valves are fully open during operation
What is the primary purpose of performing plant rounds?
To observe changing conditions during maintenance and ensure safety
What is the purpose of partially closing the gauge glass isolation valves of the safety ball check type?
To prevent the check ball from seating
What is the purpose of checking the pressure drop across the coalescing filter in the air dryer?
To determine if the filter is not plugged
What should be done with unidentified materials found in the boiler room during housekeeping?
Segregate them for safe disposal
Why is it essential to ensure the gauge glasses are stored in a safe place?
To ensure the gauge glasses are not damaged
Why is it important to check the electrolyte levels in the standby generator's batteries?
To ensure the battery charger is working correctly
What is the purpose of observing the pressure drop across the coalescing filter in the air dryer?
To determine if the filter is not plugged
What is the recommended action to take when the air inlet on the air compressor is found to be obstructed?
Clean the air inlet to ensure proper airflow
What is the primary purpose of conducting housekeeping during routine rounds in the boiler room?
To promote a safe work environment by looking for spills and leaks
What is the recommended action to take when the block heater is not operating in the standby generator?
Ensure the block heater is operating
What is the recommended frequency of checking the boiler flame failure detection systems?
Weekly
What is the purpose of simulating a flame failure condition during the testing of flame safeguard devices?
To identify potential safety issues with the boiler
What should be consulted when testing and maintaining safety limit controls on a boiler?
The operating manual supplied by the boiler manufacturer
What is the purpose of closing the main burner test firing valve during the testing of flame safeguard devices?
To simulate a flame failure condition
What is the recommended procedure for testing flame safeguard devices according to ASME BPVC VI?
By simulating a flame failure condition
Why is it important to schedule safety checks during a time when they will not adversley affect the operation of the facility?
To minimize the disruption to the facility's operations
What is critical for consistent main burner ignition?
Correct ignition sequencing
What happens when the pilot burner shuts off after the main flame trial for ignition period?
The main safety shut-off valve de-energizes
What is the recommended maintenance for programmed combustion control?
Occasional blowing out of accumulated dust
Why is it important to ensure the scanner tube has adequate air supply?
To prevent overheating of the scanner
What is the typical lifespan of an ultraviolet flame scanner?
40,000 hours
What happens when the scanner is exposed to ambient light and it fires excessively?
It needs to be replaced
What is the recommended frequency for testing the low gas pressure cut-off switch?
Monthly
What is the purpose of testing the high gas pressure cut-off switch?
To check the safety shut-off valves
Why is it important to check the flame rods regularly?
To ensure they are not warped due to heat
What is the purpose of cleaning the scanner lens?
To ensure the scanner is free from obstructions
What is the recommended action when the pilot burner test firing valve is closed?
Close the main burner test firing valve
How long should the safety shut-off valve take to close in a gas burner with an electronic flame rod?
Four seconds or less
What is the purpose of the post-purge and safety shut-down/lockout in the programmed combustion control?
To indicate a flame failure response
What should be done when the pilot burner test firing valve is closed and the pilot safety shut-off valve does not close?
Check the pilot burner for proper operation
What is the primary purpose of checking the safety shut-off valve in a gas burner with an electronic flame rod?
To verify the safety shut-off valve closes within four seconds or less
What is the recommended action when the oil solenoid valve (safety shut-off valve) does not close within four seconds or less?
Check the oil burner for proper operation
What is the purpose of covering the scanner in a gas burner with an electronic flame scanner?
To simulate a flame failure response
What is the indication of a flame failure response in a gas burner with an electronic flame rod?
The safety shut-off valve closes within four seconds or less
What is the recommended procedure when the main burner test firing valve is closed and the pilot burner test firing valve is also closed?
Start the boiler programmed combustion control
What is the purpose of the pre-purge period in the programmed combustion control?
To purge the combustion chamber
Why is it recommended to develop approved, safe, site-specific procedures for testing airflow proving switches?
To avoid explosive fuel-rich furnace conditions
What is the primary purpose of performing safety and safety relief valve tests?
To ensure the valve is functioning properly to prevent boiler damage
Why is a manual try lever test performed on a safety valve?
To ensure the valve is free to operate under pressure
What is a critical consideration when performing a manual try lever test on a power boiler in steam service?
The boiler pressure must be at least 35 kPa
Why is it essential to clear the area near the safety valve before conducting a manual try lever test on a power boiler in steam service?
To avoid steam overflow into the operating area
What is the recommended frequency of performing a pop test on a safety valve?
Annually, prior to removing the boiler from service
What is the purpose of the ASME BPVC VI and VII guidelines?
To outline the minimum frequency of safety valve checks
Why is it important to perform a manual try lever test prior to performing a pop or accumulation test on a safety valve?
To establish that the valve is free to operate under pressure
What is the critical aspect of safety valve testing that the manual try lever test does not determine?
Whether the valve will open at its set pressure
What is the recommended course of action if the safety valve continues to simmer after operating the try lever two or three times?
Repair the valve by an authorized valve repair agency
What is the indication of a leaking valve when the boiler is shut down?
Increase in water level with the make-up closed
What is the recommended frequency for dismantling and inspecting low water cut-offs, pump controls, and water feeders?
Annually
What is the purpose of checking the insulation on all wiring during annual maintenance?
To check for any deterioration and replace if necessary
What is the correct procedure for testing the high-pressure cut-off control?
Place a test lead across the terminals of the operating cut-off control and restore power to the controls
What is the purpose of conducting a pop test on a safety valve?
To check the valve's ability to open and close at the set pressure
What is the purpose of observing the cut-in and cut-off pressures during routine boiler monitoring?
To compare the operating parameters to the expected range
What should be done before performing a pop test on a safety valve?
All of the above
What is the recommended action if the safety valve fails to open at the required pressure during a pop test?
Shut off the burner and slowly release the steam pressure
What is the expected response of the high-pressure cut-off control during testing?
It should shut down the firing equipment when the steam pressure reaches the set point
What is the ASME BPVC tolerance for the set pressure of a safety valve?
Plus or minus 2 psi
What is the typical blowdown of a safety valve, as specified in the ASME BPVC?
2 psi to 4 psi
What is the purpose of evaluating the safety valve's performance against the ASME BPVC criteria?
To determine if the valve needs to be replaced or repaired
When should a pop test be performed on a safety valve?
During annual maintenance
What is the purpose of installing a temporary jumper lead during a pop test?
To bypass the operating control and high limit control
What is the recommended frequency for performing a pop test on a safety valve?
Annually
What is the purpose of recording the opening and reseating pressures of a safety valve during a pop test?
To verify the valve's ability to open and close at the set pressure
What is the purpose of the float chamber blowdown test?
To discharge sediment from the base of the float chamber
How often does ASME CSD-1 recommend performing the float chamber blowdown test for power boilers?
Daily
What should be done if the low water cut-off proves defective during testing?
Remove the boiler from service until the low water cut-off is repaired or replaced
What is the purpose of the slow drain test?
To confirm that the boiler trips at no lower than the lowest visible part of the gauge glass
What is the recommended frequency for performing the slow drain test?
Semi-annually
What is the purpose of monitoring the boiler water level closely during testing?
To prevent damage to the boiler or low water cut-off mechanism
What is the purpose of the feedwater control in a steam boiler?
To control the operation of the boiler feed pump
What should be done after testing the low water cut-off mechanism?
Reset the low water cut-off mechanism
What is the purpose of marking the levels at which the feedwater system starts and stops on the gauge glass?
To check for possible level control problems
What is the purpose of checking the make-up valve in a combined feeder/cut-off control?
To ensure that the make-up valve opens and closes properly
What is the maximum tolerance for the set pressure of a safety valve according to ASME BPVC I, Part PG-72.2?
Plus or minus 2% of the set pressure
What is the minimum blowdown required for a pressure relief valve according to ASME BPVC I, Part PG-72.1?
2 psi (15 kPa) or 2% of the set pressure
What is the purpose of an accumulation test?
To verify the installed valve capacity is sufficient
What is the acceptable pressure rise during an accumulation test for a power boiler in steam service?
6% above the highest pressure at which any valve is set
What is the purpose of a low water cut-off test?
To ensure the boiler shuts off when the water level is low
What is the recommended frequency for conducting low water cut-off tests?
As recommended by ASME CSD-1
What is the maximum allowable pressure rise during an accumulation test for a heating boiler in steam service?
5 psi (35 kPa) above the maximum allowable working pressure
What is the purpose of ASME BPVC I, Part PG-67.2?
To specify the pressure relief valve capacity for power boilers
What is the purpose of ASME BPVC IV, Part HG-512?
To specify the pressure relief valve capacity for heating boilers
What is the minimum requirement for the pressure relief valve capacity of a power boiler?
To discharge all the steam that can be generated by the boiler without allowing the pressure to rise more than 6% above the highest pressure at which any valve is set
This chapter covers the essential checks that operators must perform during their shift, including reading the log book, discussing handovers with previous shift members, and identifying specific checks for hot water or steam boilers. These activities are crucial in addition to those found in Chapter 3 Boiler Operation. Test your knowledge on the necessary boiler plant checks!
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