4BE3.5 U4 C4 Obj 1 EMH
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Questions and Answers

EASY What temperature reading on a deaerator operating at 100 kPag might not be acceptable?

  • 105°C (correct)
  • 110°C
  • 120°C
  • 100°C

    • What should you check in a sodium zeolite softener's brine tank?

  • Undissolved lumps of salt (correct)
  • Bacteria growth
  • Dissolved lumps of salt
  • Silts and sediments

    • What should the boiler temperature be at or near?

  • Low temperature set point
  • High temperature cut-off set point
  • Furnace draft temperature
  • Set point (correct)

    • What is the ideal level of water in the expansion tank?

    <p>About half way in the gauge glass</p> Signup and view all the answers

    What should you check for in hot water circulating pumps?

    <p>Unusual noise and leaks</p> Signup and view all the answers

    What may cause excessive draft loss in a boiler?

    <p>Fireside obstruction</p> Signup and view all the answers

    What is the primary goal of the handover discussion between shift members?

    <p>To discuss the plant's operating conditions during the previous shift.</p> Signup and view all the answers

    How often should a Power Engineer review the log book after a set of days off?

    <p>As far back as the last time they took charge of the plant.</p> Signup and view all the answers

    What is a sign of a properly functioning boiler?

    <p>Bright, vigorous, and symmetrical flames</p> Signup and view all the answers

    What is essential for boiler rooms?

    <p>Fresh air for ventilation and combustion air</p> Signup and view all the answers

    What is the purpose of 'rounds' in a boiler plant?

    <p>To familiarize the Power Engineer with the operating condition of all plant equipment.</p> Signup and view all the answers

    What should you check in the flue gas temperature?

    <p>Abnormally high temperatures due to over-firing</p> Signup and view all the answers

    How often should critical equipment be checked during a shift?

    <p>More often than less critical equipment.</p> Signup and view all the answers

    What should be consulted to determine the frequency of checks during rounds?

    <p>Manufacturer operations manuals and site-specific procedures.</p> Signup and view all the answers

    What should you ensure when the boiler fires?

    <p>Flames do not leave the furnace</p> Signup and view all the answers

    What senses should be used during rounds to assess the operating condition of the plant?

    <p>All senses, including touch, hearing, sight, and smell.</p> Signup and view all the answers

    Who can perform rounds in a boiler plant?

    <p>The shift engineer, the assistant shift engineer, or both.</p> Signup and view all the answers

    What is the primary purpose of log sheets during rounds?

    <p>To record test results and equipment checks.</p> Signup and view all the answers

    What is the frequency of performing boiler plant rounds?

    <p>Every 1 to 2 hours</p> Signup and view all the answers

    What is the ideal boiler water level?

    <p>About halfway up the gauge glass</p> Signup and view all the answers

    What is the objective of blowing down the water column and gauge glass?

    <p>To remove impurities from the boiler water</p> Signup and view all the answers

    What should the boiler pressure be?

    <p>Below the high-pressure cut-off setting</p> Signup and view all the answers

    Why should the lube oil temperature be checked?

    <p>To ensure it is not overheating</p> Signup and view all the answers

    What should be checked in the condensate receiver?

    <p>The pH and hardness of the condensate</p> Signup and view all the answers

    What is the purpose of the deaerator?

    <p>To remove air from the boiler feedwater</p> Signup and view all the answers

    What should the deaerator water level be?

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

    What should the deaerator pressure be?

    <p>Between 70 and 400 kPa</p> Signup and view all the answers

    What is the correlation between the deaerator water temperature and steam pressure?

    <p>The water temperature correlates to the saturation temperature of water at the steam pressure</p> Signup and view all the answers

    What may block air from entering the boiler room?

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

    Who typically conducts plant rounds?

    <p>Assistant shift engineer</p> Signup and view all the answers

    What is the importance of checking the air compressor?

    <p>To drive automatic valves and damper positioners</p> Signup and view all the answers

    Why is it essential to check the air receiver pressure?

    <p>To confirm it is at or near the set point</p> Signup and view all the answers

    What should be checked on the air dryer?

    <p>Dew point of the compressed air</p> Signup and view all the answers

    Why is it necessary to check the standby generator?

    <p>To ensure it is ready to start without delay in the event of a power failure</p> Signup and view all the answers

    What is the primary goal of housekeeping during routine rounds?

    <p>To promote a safe work environment</p> Signup and view all the answers

    What should be done with spilled materials?

    <p>Clean them up immediately</p> Signup and view all the answers

    What should engineers observe during ongoing maintenance?

    <p>Hazards created during maintenance</p> Signup and view all the answers

    Why is it essential to check the electrolyte levels in the batteries?

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

    What should be stored in a safe place to prevent damage?

    <p>Gauge glasses</p> Signup and view all the answers

    What is the purpose of monitoring feedwater level controllers?

    <p>To maintain the boiler water level at set point</p> Signup and view all the answers

    What is an indication of a failed steam trap?

    <p>Constant flow of steam from the test valve</p> Signup and view all the answers

    What should be checked regularly to ensure proper operation?

    <p>Steam traps</p> Signup and view all the answers

    What is the result of a steam trap that passes steam?

    <p>Energy is wasted</p> Signup and view all the answers

    What is the purpose of a direct method of checking a steam trap?

    <p>To confirm the steam trap is functioning correctly</p> Signup and view all the answers

    What is used to compare the trap inlet temperature to the trap outlet temperature?

    <p>Hand-held infrared thermometer</p> Signup and view all the answers

    What is the result of a steam trap that is plugged?

    <p>Condensate floods heat exchangers</p> Signup and view all the answers

    What should be done at the beginning of every shift?

    <p>Complete a water column blowdown</p> Signup and view all the answers

    Why should the water column be blown down every shift?

    <p>To remove sediment that may collect</p> Signup and view all the answers

    What should be checked first when taking charge of a boiler?

    <p>The adequate water level</p> Signup and view all the answers

    What should be done to prevent tripping hazards?

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

    What should be done when the gauge glass becomes obscured by internal corrosion or deposits?

    <p>Replace the gauge glass</p> Signup and view all the answers

    What is the purpose of the procedure for clearing the passages on the water column and gauge glass?

    <p>To prove the connections are clear</p> Signup and view all the answers

    How often should the water column and gauge glass be blown down on smaller high-pressure boilers?

    <p>Every shift</p> Signup and view all the answers

    What should be checked to ensure the water column is not obstructed?

    <p>The water column connections</p> Signup and view all the answers

    Why should frequent blowdown be avoided on large boilers with mica gauge glasses?

    <p>To reduce maintenance costs</p> Signup and view all the answers

    What should be done when the water column is being put back in operation?

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

    What should the boiler feed pumps be checked for?

    <p>Vibration, unusual noise, leaks, and discharge pressure</p> Signup and view all the answers

    What should be checked in the condensate receiver?

    <p>Level and pH</p> Signup and view all the answers

    Why should the lube oil temperature be checked?

    <p>To ensure the lube oil cooler is functioning properly</p> Signup and view all the answers

    What should the deaerator pressure be?

    <p>Between 70 and 400 kPa</p> Signup and view all the answers

    What is the purpose of the deaerator?

    <p>To remove non-condensable gases from the feedwater</p> Signup and view all the answers

    MEDIUM What should the boiler water level be?

    <p>Halfway up the gauge glass</p> Signup and view all the answers

    What should the boiler pressure be?

    <p>At or near the set point</p> Signup and view all the answers

    Why should the pump packing be adjusted?

    <p>If shaft leakage is excessive</p> Signup and view all the answers

    What is the correlation between the deaerator water temperature and steam pressure?

    <p>The temperature should correlate to the saturation temperature of water at the steam pressure</p> Signup and view all the answers

    What should be ensured when checking the condensate transfer pumps?

    <p>That the standby pump is ready to be put in service</p> Signup and view all the answers

    What is the main purpose of reading the log book before starting a shift?

    <p>To become familiar with the operating condition of the plant</p> Signup and view all the answers

    How often should a Power Engineer review the log book after a set of days off?

    <p>As soon as they return to shift</p> Signup and view all the answers

    What is the purpose of doing 'rounds' in a boiler plant?

    <p>To become familiar with the operating condition of the plant</p> Signup and view all the answers

    What should be used to assess the operating condition of the plant during rounds?

    <p>All the senses (sight, sound, touch, smell)</p> Signup and view all the answers

    What should be consulted to determine the frequency of checks during rounds?

    <p>Both manufacturer operations manuals and site-specific procedures</p> Signup and view all the answers

    Who may perform rounds in a boiler plant?

    <p>Both the shift engineer and the assistant shift engineer</p> Signup and view all the answers

    What is the primary purpose of the handover discussion between shift members?

    <p>To discuss the activities of the previous shift</p> Signup and view all the answers

    How often should critical equipment be checked during a shift?

    <p>More often than less critical equipment</p> Signup and view all the answers

    What is the primary purpose of checking the linkage on the intake louvres?

    <p>To check for corrosion and ensure free operation.</p> Signup and view all the answers

    What is the importance of checking the air receiver pressure?

    <p>To ensure the air compressor is operating correctly.</p> Signup and view all the answers

    What should be checked on the air dryer?

    <p>The dew point of the compressed air.</p> Signup and view all the answers

    Why is it essential to check the electrolyte levels in the batteries?

    <p>To ensure the standby generator is ready to start.</p> Signup and view all the answers

    What is the primary goal of housekeeping during routine rounds?

    <p>To promote a safe work environment.</p> Signup and view all the answers

    What should be done with spilled materials?

    <p>Clean them up immediately using appropriate methods.</p> Signup and view all the answers

    What is the purpose of checking the brine tank level in a sodium zeolite softener?

    <p>To ensure proper regeneration</p> Signup and view all the answers

    What should engineers observe during ongoing maintenance?

    <p>Changing conditions that may create new hazards.</p> Signup and view all the answers

    What is the primary reason for checking the flow totalizer in an ion-exchange softener?

    <p>To determine when regeneration is necessary</p> Signup and view all the answers

    What is the purpose of checking the air inlet on the air compressor?

    <p>To ensure the air inlet is free of obstruction.</p> Signup and view all the answers

    What is the ideal temperature of the boiler during operation?

    <p>At or near the set point</p> Signup and view all the answers

    What should be ensured when the compressor is fed with outside air?

    <p>The air inlet is free of obstruction.</p> Signup and view all the answers

    What is the purpose of monitoring the expansion tank level?

    <p>To maintain the ideal water level</p> Signup and view all the answers

    What should be checked on the standby generator?

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

    What should be checked during hot water circulating pump operation?

    <p>Vibration, noise, discharge pressure, and leaks</p> Signup and view all the answers

    Why is it important to check the furnace draft gauges?

    <p>To check for excessive draft loss</p> Signup and view all the answers

    What may cause an abnormally high flue gas temperature?

    <p>Over-firing or too much excess air</p> Signup and view all the answers

    What should be ensured when the boiler fires?

    <p>That flames do not leave the furnace</p> Signup and view all the answers

    Why is it essential to supply fresh air to boiler rooms?

    <p>For combustion air and ventilation</p> Signup and view all the answers

    What should be checked regularly to ensure proper system operation?

    <p>Pumps, valves, boilers, and heaters</p> Signup and view all the answers

    What should be checked to ensure the water column is not obstructed, thereby giving a false level indication?

    <p>Steam side and waterside isolating valves</p> Signup and view all the answers

    What is the purpose of blowing down the water column and gauge glass?

    <p>To remove any sediment that may collect</p> Signup and view all the answers

    What should be done to prevent tripping hazards during plant rounds?

    <p>Both A and B</p> Signup and view all the answers

    What should be checked first when taking charge of a boiler?

    <p>Adequate water level</p> Signup and view all the answers

    What should be done to prove the steam connection is clear in the water column?

    <p>Close the water column steam valve and open the water column drain valve</p> Signup and view all the answers

    Why is it necessary to blow down the gauge glass less frequently on large boilers?

    <p>To prolong the life of the mica and reduce maintenance costs</p> Signup and view all the answers

    What should be done to prove the water connection is clear in the water column?

    <p>Close the water column drain valve and open the water column water valve</p> Signup and view all the answers

    What should be checked to ensure the gauge glass is not obstructed?

    <p>Piping connections from the water column to both the boiler and the gauge</p> Signup and view all the answers

    What should be done to put the water column back in operation after blowdown?

    <p>Close the water column drain valve and open the water column steam valve</p> Signup and view all the answers

    What should be done to prove the lower gauge glass connection is clear?

    <p>Close the gauge glass water valve and open the gauge glass drain valve</p> Signup and view all the answers

    Why should gauge glasses be stored in a safe place?

    <p>To prevent them from getting damaged</p> Signup and view all the answers

    What should be monitored regularly to ensure the boiler water level is at set point?

    <p>Feedwater level controllers</p> Signup and view all the answers

    What is a sign of a failed steam trap?

    <p>Constant flow of steam</p> Signup and view all the answers

    How can the operation of a steam trap be checked indirectly?

    <p>By using a hand-held infrared thermometer</p> Signup and view all the answers

    What is the result of a steam trap that is plugged?

    <p>It causes condensate to flood heat exchangers</p> Signup and view all the answers

    What is the purpose of testing the feedwater control valve?

    <p>To ensure the boiler water level remains at set point</p> Signup and view all the answers

    Why should washers or packing rings be stored with gauge glasses?

    <p>To prevent them from getting damaged</p> Signup and view all the answers

    What should be done to check a steam trap directly?

    <p>Open the test valve downstream of the trap and observe the steam flow</p> Signup and view all the answers

    What is a crucial aspect of the handover discussion between shift members?

    <p>Discussing the operation of critical equipment</p> Signup and view all the answers

    How often should a Power Engineer review the log book after a set of days off?

    <p>After every set of days off, reading back to the last time they took charge</p> Signup and view all the answers

    What is the primary purpose of 'rounds' in a boiler plant?

    <p>To monitor the performance of critical equipment</p> Signup and view all the answers

    Who is responsible for performing rounds in a boiler plant?

    <p>Both the shift engineer and the assistant shift engineer</p> Signup and view all the answers

    What senses should be used during rounds to assess the operating condition of the plant?

    <p>All the senses: sight, sound, touch, smell, and hearing</p> Signup and view all the answers

    What is the primary purpose of log sheets during rounds?

    <p>To record any unusual occurrences or issues</p> Signup and view all the answers

    What should a Power Engineer do at the beginning of every shift?

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

    Why is it essential to have a comprehensive set of rounds?

    <p>To assess the operating condition of all plant equipment</p> Signup and view all the answers

    What is the primary purpose of checking the flow totalizer in an ion-exchange softener?

    <p>To determine when a regeneration is necessary</p> Signup and view all the answers

    What is the ideal condition for the furnace draft in a boiler?

    <p>Correct draft with a normal temperature</p> Signup and view all the answers

    What is the purpose of checking the expansion tank level in a hot water boiler plant?

    <p>To ensure the level is halfway in the gauge glass</p> Signup and view all the answers

    What is the result of a high flue gas temperature in a boiler?

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

    What should be checked to ensure proper ventilation and combustion air supply in a boiler room?

    <p>Air dampers and louvres</p> Signup and view all the answers

    What is the purpose of checking the pumping packing in hot water circulating pumps?

    <p>To adjust the pump packing if shaft leakage is excessive</p> Signup and view all the answers

    What should be done if the safety valves on the boilers or heating system are lifting?

    <p>Investigate and correct the cause</p> Signup and view all the answers

    What is the purpose of checking the operation of the system safety valves in a hot water boiler plant?

    <p>To check for leaks and observe the expansion tank level</p> Signup and view all the answers

    What is the ideal condition of the flame in a boiler?

    <p>Bright and free of soot</p> Signup and view all the answers

    What should be checked to ensure proper combustion air supply in a boiler room?

    <p>Air dampers and louvres</p> Signup and view all the answers

    What is the primary purpose of checking the air compressor?

    <p>To check the pressure of compressed air in the air receiver</p> Signup and view all the answers

    What is the purpose of checking the dew point of the compressed air?

    <p>To ensure the air dryer is functioning correctly</p> Signup and view all the answers

    What is the primary purpose of conducting plant rounds?

    <p>To identify potential hazards and take corrective action</p> Signup and view all the answers

    What is the purpose of checking the electrolyte levels in the batteries?

    <p>To ensure the standby generator is ready to start</p> Signup and view all the answers

    What is the primary goal of housekeeping during routine rounds?

    <p>To clean up spills and leaks</p> Signup and view all the answers

    What is the purpose of checking the air receiver pressure?

    <p>To ensure the air compressor is functioning correctly</p> Signup and view all the answers

    What is the primary purpose of checking the standby generator?

    <p>To ensure the standby generator is ready to start in the event of a power failure</p> Signup and view all the answers

    What is the purpose of checking the compressor lube oil pump pressure?

    <p>To ensure the air compressor is functioning correctly</p> Signup and view all the answers

    What is the primary purpose of observing changing conditions during ongoing maintenance?

    <p>To identify potential hazards and take corrective action</p> Signup and view all the answers

    What is the purpose of checking the block heater on the standby generator?

    <p>To ensure the standby generator is ready to start</p> Signup and view all the answers

    What is the primary purpose of checking the boiler firing rate during rounds?

    <p>To adjust the steam demand and maintain steam pressure at the set point</p> Signup and view all the answers

    What is an indication of corrosion in the condensate return system?

    <p>Rusty colored condensate</p> Signup and view all the answers

    What is the purpose of checking the lube oil temperature during boiler plant rounds?

    <p>To adjust the lube oil cooling water flow</p> Signup and view all the answers

    What is the normal operating pressure range of a deaerator?

    <p>Between 70 and 400 kPa</p> Signup and view all the answers

    What should be done to the condensate tank float switch during rounds?

    <p>It should be manually activated to start the pump</p> Signup and view all the answers

    What is the correlation between the deaerator water temperature and steam pressure?

    <p>The water temperature correlates to the saturation temperature of water at the steam pressure</p> Signup and view all the answers

    What is the purpose of checking the boiler feed pumps during rounds?

    <p>To check for vibration, unusual noise, leaks, and discharge pressure</p> Signup and view all the answers

    What should be done to the pump packing if shaft leakage is excessive during boiler plant rounds?

    <p>It should be adjusted to reduce leakage</p> Signup and view all the answers

    What is the purpose of checking the steam pressure during boiler plant rounds?

    <p>To ensure the steam header pressure is normal</p> Signup and view all the answers

    What should be done to the standby pump during boiler plant rounds?

    <p>It should be checked to ensure it is ready to be put in service if the primary pump fails</p> Signup and view all the answers

    What is the primary purpose of monitoring feedwater level controllers?

    <p>To maintain the boiler water level at set point</p> Signup and view all the answers

    What is the result of a steam trap that passes steam?

    <p>Significant energy waste</p> Signup and view all the answers

    What is used to compare the trap inlet temperature to the trap outlet temperature?

    <p>A hand-held infrared thermometer</p> Signup and view all the answers

    What is the result of a steam trap that is plugged?

    <p>Condensate flooding of heat exchangers</p> Signup and view all the answers

    What should be stored in a safe place to prevent damage?

    <p>Gauge glasses and washers</p> Signup and view all the answers

    What is the purpose of a direct method of checking a steam trap?

    <p>To determine if the trap is functioning correctly</p> Signup and view all the answers

    What should be checked regularly to ensure proper operation?

    <p>Feedwater level controllers and steam traps</p> Signup and view all the answers

    What is an indication of a failed steam trap?

    <p>Constant flow of steam from the test valve</p> Signup and view all the answers

    What is the primary purpose of isolating the water column during maintenance?

    <p>To prevent steam from flowing through the gauge glass</p> Signup and view all the answers

    Why is it necessary to blow down the gauge glass steam valve and drain valve?

    <p>To clear the steam connection and gauge glass</p> Signup and view all the answers

    What is the recommended procedure for blowing down the water column when equipped with isolation valves?

    <p>Close the water column steam valve, open the water column drain valve, and then open the water column steam valve</p> Signup and view all the answers

    What is the purpose of the water column blowdown procedure?

    <p>To prove the water column connections are clear</p> Signup and view all the answers

    What should be done to prevent tripping hazards during maintenance?

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

    Why is it necessary to check the water column connections before blowing down the water column?

    <p>To ensure the water column is not obstructed</p> Signup and view all the answers

    What should be done to the water column drain valve after blowing down the water column?

    <p>Close the valve</p> Signup and view all the answers

    Why is it recommended to blow down the water column every shift?

    <p>To remove sediment from the water column</p> Signup and view all the answers

    What should be checked first when taking charge of a boiler?

    <p>The water level</p> Signup and view all the answers

    Why is it necessary to check the steam side and waterside isolating valves when equipped?

    <p>To ensure the valves are fully open</p> Signup and view all the answers

    Study Notes

    Operator Rounds

    • Before starting a shift, operators must have a handover discussion with the previous shift members, read the log book, and review log sheets to become familiar with the operating condition of all plant equipment.
    • Operator rounds involve using all senses to assess the operating condition of the plant, including testing and formal log sheet entries.
    • Rounds may be done by the shift engineer, assistant shift engineer, or both, and may take one to two hours to complete.

    Boiler Plant Rounds

    • The shift engineer usually performs the boiler plant rounds.
    • Checks to be performed during boiler plant rounds include:
      • Water level: ensure the boiler water level is at set point (about half way up the gauge glass).
      • Blow down the water column, gauge glass, low water cut-offs, water feeders, feedwater flow transmitter, and drum level transmitter.
      • Steam pressure: ensure the main steam header pressure is normal and the boiler pressure is at or near set point.
      • Boiler firing rate: ensure the boiler firing rate varies with steam demand to maintain steam pressure at set point.
      • Boiler feed pumps: check for vibration, unusual noise, leaks, and discharge pressure.
      • Condensate receiver: check the level, pH, and hardness of the condensate.
      • Condensate transfer pumps: check for vibration, unusual noise, leaks, and discharge pressure.
      • Deaerator: ensure the deaerator water level is normal, and the deaerator vent valve is open.

    Hot Water Boiler Plant Rounds

    • Checks to be performed during hot water boiler plant rounds include:
      • Hot water temperature: ensure the boiler temperature is at or near set point.
      • Expansion tank: check the level of water in the expansion tank.
      • Circulating pumps: check for vibration, unusual noise, leaks, and discharge pressure.

    Common Boiler Plant Rounds

    • Checks to be performed during common boiler plant rounds include:
      • Boiler draft: check the furnace draft gauges and ensure the draft is correct.
      • Flue gas temperature: observe the flue gas temperature when the boiler is warmed up and firing.
      • Flame condition: ensure the flame is bright, free of soot, and does not impinge on any heat transfer surface.
      • Ventilation and combustion air supply: ensure the air openings into the boiler room are unobstructed.
      • Plant rounds: the assistant shift engineer usually conducts the plant rounds.

    Air Compressor

    • Checks to be performed during air compressor rounds include:
      • Pressure: ensure the compressed air pressure is at or near set point.
      • Blow off water from the base of the air receiver.
      • Cooling water flow: ensure adequate cooling water flow through the aftercooler.
      • Compressor lube oil pump pressure: ensure it is operating according to manufacturer's specifications.

    Air Dryer

    • Checks to be performed during air dryer rounds include:
      • Dew point: ensure the dew point is adequate according to the air dryer design and plant requirements.
      • Coalescing filter: ensure the pressure drop across the coalescing filter is not too great.

    Standby Generator

    • Checks to be performed during standby generator rounds include:
      • Battery charger: ensure the battery charger is working correctly.
      • Electrolyte levels: ensure the electrolyte levels in the batteries are adequate.
      • Block heater: ensure the block heater is operating and the engine is warm or hot.
      • Lube oil pressure and temperature: ensure they meet manufacturer specifications.

    Housekeeping

    • Overall housekeeping during routine rounds helps to promote a safe work environment.
    • Checks to be performed during housekeeping rounds include:
      • Look for spills and leaks, and clean them up immediately.
      • Ensure chemicals are correctly stored and labelled.
      • Look for tripping hazards and return tools to their proper locations.
      • Assess lighting and report any areas that need replacement lamps.

    Ongoing Maintenance

    • Engineers must be aware of changing conditions due to ongoing power plant maintenance.
    • Checks to be performed during ongoing maintenance rounds include:
      • Look for leaks and clean them up.
      • Be aware of tripping hazards created by drain hoses or power cords.
      • Check for open floor grates that were removed to facilitate maintenance.

    Water Column Blowdown

    • A water column blowdown should be completed at the beginning of every shift.
    • The procedure for blowing down the water column includes:
      1. Isolate the water column.
      2. Blow down the water column.
      3. Place the water column back in service.
      4. Blow down the gauge glass.
      5. Place the gauge glass back in service.

    Water Level Control

    • Feedwater level controllers must be monitored regularly to ensure they maintain the boiler water level at set point.
    • The procedure for testing the operation of the feedwater control valve includes:
      1. Close the isolation valve downstream of the feedwater valve.
      2. Observe changes in the valve position as the boiler level drops.
      3. Confirm that the feedwater control valve is responding correctly.
      4. Re-open the downstream isolating valve.
      5. Ensure the boiler water level returns to set point.

    Steam Traps

    • Steam traps should be observed for proper operation on a regular basis.
    • The procedure for checking steam traps includes:
      1. Close the isolation valve downstream of the trap.
      2. Open a test valve located downstream of the trap.
      3. Observe steam flow from the test valve.
      4. If there is a constant flow of steam, the trap has failed.
      5. If there is intermittent condensate flow, the trap is functioning correctly.

    Operator Rounds

    • Before starting a shift, operators must have a handover discussion with the previous shift members, read the log book, and review log sheets to become familiar with the operating condition of all plant equipment.
    • Operator rounds involve using all senses to assess the operating condition of the plant, including testing and formal log sheet entries.
    • Rounds may be done by the shift engineer, assistant shift engineer, or both, and may take one to two hours to complete.

    Boiler Plant Rounds

    • The shift engineer usually performs the boiler plant rounds.
    • Checks to be performed during boiler plant rounds include:
      • Water level: ensure the boiler water level is at set point (about half way up the gauge glass).
      • Blow down the water column, gauge glass, low water cut-offs, water feeders, feedwater flow transmitter, and drum level transmitter.
      • Steam pressure: ensure the main steam header pressure is normal and the boiler pressure is at or near set point.
      • Boiler firing rate: ensure the boiler firing rate varies with steam demand to maintain steam pressure at set point.
      • Boiler feed pumps: check for vibration, unusual noise, leaks, and discharge pressure.
      • Condensate receiver: check the level, pH, and hardness of the condensate.
      • Condensate transfer pumps: check for vibration, unusual noise, leaks, and discharge pressure.
      • Deaerator: ensure the deaerator water level is normal, and the deaerator vent valve is open.

    Hot Water Boiler Plant Rounds

    • Checks to be performed during hot water boiler plant rounds include:
      • Hot water temperature: ensure the boiler temperature is at or near set point.
      • Expansion tank: check the level of water in the expansion tank.
      • Circulating pumps: check for vibration, unusual noise, leaks, and discharge pressure.

    Common Boiler Plant Rounds

    • Checks to be performed during common boiler plant rounds include:
      • Boiler draft: check the furnace draft gauges and ensure the draft is correct.
      • Flue gas temperature: observe the flue gas temperature when the boiler is warmed up and firing.
      • Flame condition: ensure the flame is bright, free of soot, and does not impinge on any heat transfer surface.
      • Ventilation and combustion air supply: ensure the air openings into the boiler room are unobstructed.
      • Plant rounds: the assistant shift engineer usually conducts the plant rounds.

    Air Compressor

    • Checks to be performed during air compressor rounds include:
      • Pressure: ensure the compressed air pressure is at or near set point.
      • Blow off water from the base of the air receiver.
      • Cooling water flow: ensure adequate cooling water flow through the aftercooler.
      • Compressor lube oil pump pressure: ensure it is operating according to manufacturer's specifications.

    Air Dryer

    • Checks to be performed during air dryer rounds include:
      • Dew point: ensure the dew point is adequate according to the air dryer design and plant requirements.
      • Coalescing filter: ensure the pressure drop across the coalescing filter is not too great.

    Standby Generator

    • Checks to be performed during standby generator rounds include:
      • Battery charger: ensure the battery charger is working correctly.
      • Electrolyte levels: ensure the electrolyte levels in the batteries are adequate.
      • Block heater: ensure the block heater is operating and the engine is warm or hot.
      • Lube oil pressure and temperature: ensure they meet manufacturer specifications.

    Housekeeping

    • Overall housekeeping during routine rounds helps to promote a safe work environment.
    • Checks to be performed during housekeeping rounds include:
      • Look for spills and leaks, and clean them up immediately.
      • Ensure chemicals are correctly stored and labelled.
      • Look for tripping hazards and return tools to their proper locations.
      • Assess lighting and report any areas that need replacement lamps.

    Ongoing Maintenance

    • Engineers must be aware of changing conditions due to ongoing power plant maintenance.
    • Checks to be performed during ongoing maintenance rounds include:
      • Look for leaks and clean them up.
      • Be aware of tripping hazards created by drain hoses or power cords.
      • Check for open floor grates that were removed to facilitate maintenance.

    Water Column Blowdown

    • A water column blowdown should be completed at the beginning of every shift.
    • The procedure for blowing down the water column includes:
      1. Isolate the water column.
      2. Blow down the water column.
      3. Place the water column back in service.
      4. Blow down the gauge glass.
      5. Place the gauge glass back in service.

    Water Level Control

    • Feedwater level controllers must be monitored regularly to ensure they maintain the boiler water level at set point.
    • The procedure for testing the operation of the feedwater control valve includes:
      1. Close the isolation valve downstream of the feedwater valve.
      2. Observe changes in the valve position as the boiler level drops.
      3. Confirm that the feedwater control valve is responding correctly.
      4. Re-open the downstream isolating valve.
      5. Ensure the boiler water level returns to set point.

    Steam Traps

    • Steam traps should be observed for proper operation on a regular basis.
    • The procedure for checking steam traps includes:
      1. Close the isolation valve downstream of the trap.
      2. Open a test valve located downstream of the trap.
      3. Observe steam flow from the test valve.
      4. If there is a constant flow of steam, the trap has failed.
      5. If there is intermittent condensate flow, the trap is functioning correctly.

    Operator Rounds

    • Before starting a shift, operators must have a handover discussion with the previous shift members, read the log book, and review log sheets to become familiar with the operating condition of all plant equipment.
    • Operator rounds involve using all senses to assess the operating condition of the plant, including testing and formal log sheet entries.
    • Rounds may be done by the shift engineer, assistant shift engineer, or both, and may take one to two hours to complete.

    Boiler Plant Rounds

    • The shift engineer usually performs the boiler plant rounds.
    • Checks to be performed during boiler plant rounds include:
      • Water level: ensure the boiler water level is at set point (about half way up the gauge glass).
      • Blow down the water column, gauge glass, low water cut-offs, water feeders, feedwater flow transmitter, and drum level transmitter.
      • Steam pressure: ensure the main steam header pressure is normal and the boiler pressure is at or near set point.
      • Boiler firing rate: ensure the boiler firing rate varies with steam demand to maintain steam pressure at set point.
      • Boiler feed pumps: check for vibration, unusual noise, leaks, and discharge pressure.
      • Condensate receiver: check the level, pH, and hardness of the condensate.
      • Condensate transfer pumps: check for vibration, unusual noise, leaks, and discharge pressure.
      • Deaerator: ensure the deaerator water level is normal, and the deaerator vent valve is open.

    Hot Water Boiler Plant Rounds

    • Checks to be performed during hot water boiler plant rounds include:
      • Hot water temperature: ensure the boiler temperature is at or near set point.
      • Expansion tank: check the level of water in the expansion tank.
      • Circulating pumps: check for vibration, unusual noise, leaks, and discharge pressure.

    Common Boiler Plant Rounds

    • Checks to be performed during common boiler plant rounds include:
      • Boiler draft: check the furnace draft gauges and ensure the draft is correct.
      • Flue gas temperature: observe the flue gas temperature when the boiler is warmed up and firing.
      • Flame condition: ensure the flame is bright, free of soot, and does not impinge on any heat transfer surface.
      • Ventilation and combustion air supply: ensure the air openings into the boiler room are unobstructed.
      • Plant rounds: the assistant shift engineer usually conducts the plant rounds.

    Air Compressor

    • Checks to be performed during air compressor rounds include:
      • Pressure: ensure the compressed air pressure is at or near set point.
      • Blow off water from the base of the air receiver.
      • Cooling water flow: ensure adequate cooling water flow through the aftercooler.
      • Compressor lube oil pump pressure: ensure it is operating according to manufacturer's specifications.

    Air Dryer

    • Checks to be performed during air dryer rounds include:
      • Dew point: ensure the dew point is adequate according to the air dryer design and plant requirements.
      • Coalescing filter: ensure the pressure drop across the coalescing filter is not too great.

    Standby Generator

    • Checks to be performed during standby generator rounds include:
      • Battery charger: ensure the battery charger is working correctly.
      • Electrolyte levels: ensure the electrolyte levels in the batteries are adequate.
      • Block heater: ensure the block heater is operating and the engine is warm or hot.
      • Lube oil pressure and temperature: ensure they meet manufacturer specifications.

    Housekeeping

    • Overall housekeeping during routine rounds helps to promote a safe work environment.
    • Checks to be performed during housekeeping rounds include:
      • Look for spills and leaks, and clean them up immediately.
      • Ensure chemicals are correctly stored and labelled.
      • Look for tripping hazards and return tools to their proper locations.
      • Assess lighting and report any areas that need replacement lamps.

    Ongoing Maintenance

    • Engineers must be aware of changing conditions due to ongoing power plant maintenance.
    • Checks to be performed during ongoing maintenance rounds include:
      • Look for leaks and clean them up.
      • Be aware of tripping hazards created by drain hoses or power cords.
      • Check for open floor grates that were removed to facilitate maintenance.

    Water Column Blowdown

    • A water column blowdown should be completed at the beginning of every shift.
    • The procedure for blowing down the water column includes:
      1. Isolate the water column.
      2. Blow down the water column.
      3. Place the water column back in service.
      4. Blow down the gauge glass.
      5. Place the gauge glass back in service.

    Water Level Control

    • Feedwater level controllers must be monitored regularly to ensure they maintain the boiler water level at set point.
    • The procedure for testing the operation of the feedwater control valve includes:
      1. Close the isolation valve downstream of the feedwater valve.
      2. Observe changes in the valve position as the boiler level drops.
      3. Confirm that the feedwater control valve is responding correctly.
      4. Re-open the downstream isolating valve.
      5. Ensure the boiler water level returns to set point.

    Steam Traps

    • Steam traps should be observed for proper operation on a regular basis.
    • The procedure for checking steam traps includes:
      1. Close the isolation valve downstream of the trap.
      2. Open a test valve located downstream of the trap.
      3. Observe steam flow from the test valve.
      4. If there is a constant flow of steam, the trap has failed.
      5. If there is intermittent condensate flow, the trap is functioning correctly.

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    Description

    This chapter covers the fundamental and necessary checks that operators must perform on a boiler plant during their shift, including handover discussions and log book reviews.

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