Boiler Safety Valve Testing Procedure
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Questions and Answers

What is the recommended time for the safety shut-off valve to close after the main burner test firing valve is closed for a gas burner with an interrupted pilot?

  • Exactly four seconds
  • Less than four seconds (correct)
  • More than four seconds
  • Depends on the scanner operation

What should be done if the ultraviolet scanner fires excessively when exposed to ambient light?

  • It does not require any action
  • Clean the scanner lens regularly
  • Replace the scanner (correct)
  • Increase the ambient light exposure

How often does ASME CSD-1 recommend replacing flame rods and scanners?

  • Monthly
  • Bi-monthly
  • Bi-annually
  • Annually (correct)

What is the purpose of the post-purge and safety shut-down/lockout in the programmed combustion control?

<p>To clear any remaining combustible gases (C)</p> Signup and view all the answers

What is the recommended frequency for testing the low gas pressure cut-off switch according to ASME CSD-1?

<p>Monthly (C)</p> Signup and view all the answers

How can the low gas pressure cut-off be tested during the operation of the boiler?

<p>By quickly closing the main gas valve upstream of the low gas pressure switch (D)</p> Signup and view all the answers

What is recommended for testing combustion air proving switches?

<p>Developing approved, safe, site-specific procedures for testing airflow proving switches (D)</p> Signup and view all the answers

What should be done prior to performing a pop test on safety valves?

<p>Performing a try lever test to ensure the safety valve is not seized (C)</p> Signup and view all the answers

What is important before conducting a manual try lever test for heating boilers in steam service?

<p>Ensuring that all personnel are cleared from the area near the safety valve before conducting a manual try lever test (D)</p> Signup and view all the answers

What should be done if a safety valve continues to simmer during a manual try lever test?

<p>The valve must be replaced or repaired by an authorized valve repair agency (D)</p> Signup and view all the answers

What is the purpose of rapidly draining the float chamber in a boiler?

<p>To discharge sediment from the base of the float chamber (C)</p> Signup and view all the answers

How often should the float chamber blowdown test be completed for power boilers according to ASME CSD-1?

<p>Daily (A)</p> Signup and view all the answers

What is the recommended frequency for completing the slow drain test for boilers according to ASME CSD-1?

<p>Semi-annually (B)</p> Signup and view all the answers

How can the operation of a feedwater solenoid valve be checked?

<p>By observing the levels at which the feedwater system starts and stops (D)</p> Signup and view all the answers

What should be done annually as part of the maintenance and inspection of water level controls?

<p>Inspecting electrical contacts for cleanliness (B)</p> Signup and view all the answers

What should be done if the safety valve fails to open at the required pressure?

<p>Apply the try lever test a few times and repeat the pop test (A)</p> Signup and view all the answers

What is the acceptable range for the safety valve to open during the pop test according to ASME BPVC?

<p>13 to 17 psi (85 to 115 kPa) (D)</p> Signup and view all the answers

What does ASME BPVC state regarding the blowdown of safety valves?

<p>Blowdown should be between 2 to 4 psi (15 to 30 kPa) (D)</p> Signup and view all the answers

What is the purpose of an accumulation test for safety valves?

<p>To verify if the installed safety valve capacity is sufficient (B)</p> Signup and view all the answers

What is the maximum acceptable pressure during an accumulation test for a boiler with a MAWP of 1380 kPa and a safety valve set to 1310 kPa?

<p>1389 kPa (D)</p> Signup and view all the answers

What is the recommended frequency for testing the boiler flame failure detection systems?

<p>Weekly (B)</p> Signup and view all the answers

When testing the flame failure device on a boiler, what is necessary to simulate?

<p>Flame failure condition (B)</p> Signup and view all the answers

According to ASME BPVC VI, what does the recommended procedure describe the testing of?

<p>Flame safeguard devices (C)</p> Signup and view all the answers

What should be closed to test the gas burner with a thermocouple or thermopile flame sensor?

<p>Main burner test firing valve (B)</p> Signup and view all the answers

What is important to follow when testing various devices according to the text?

<p>Manufacturer testing instructions (D)</p> Signup and view all the answers

What is the purpose of the flow switch in a copper tubular and copper fin-tube boiler?

<p>To provide positive water circulation to protect heat transfer surfaces (B)</p> Signup and view all the answers

How can the flow switch in a copper tubular and copper fin-tube boiler be tested?

<p>By slowly closing the boiler outlet valve and observing the burner (A)</p> Signup and view all the answers

What is a recommended means for testing the operation of the external low-water fuel cut-off without draining the entire system?

<p>Installing special combination test and check valves (C)</p> Signup and view all the answers

How often does ASME BPVC VI recommend testing the low water cut-off of hot water heating boilers?

<p>Monthly (D)</p> Signup and view all the answers

What is the purpose of the high temperature cut-off in a boiler?

<p>To protect against overheating by shutting off power to the controls (B)</p> Signup and view all the answers

Flashcards

Gas Burner Safety Shut-off

The safety valve needs to close within a specified time after the burner's pilot valve is shut off.

UV Scanner Adjustment

If a UV scanner is reacting excessively to ambient light, adjust its position or relocate it for better performance.

Flame Rod/Scanner Replacement

These components should be replaced every 1-2 years or as per manufacturer's instructions.

Post-Purge and Safety Shutdown

This process prevents gas leaks and ensures safe operation of the burner.

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Low Gas Pressure Cut-off Test

Test this switch every 30 days by simulating low gas pressure (observe gauge/alarm).

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Combustion Air Proving Switch Test

Test this switch every 30 days as per ASME CSD-1.

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Safety Valve Pop Test Procedure

Follow all safety procedures before performing a pop test on safety valves.

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Heating Boiler Try Lever Test

Ensure the boiler is operating and has minimum pressure before manually testing the try lever.

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Faulty Safety Valve Indication

A safety valve that continues to simmer during the manual test might be faulty and needs replacement.

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Float Chamber Blowdown

Drain the float chamber regularly to prevent corrosion and sediment buildup.

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Float Chamber Blowdown Frequency

Power boilers must have a float chamber blowdown test every 31 days.

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Slow Drain Test Frequency

Slow drain tests should be conducted every 366 days in boilers.

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Feedwater Solenoid Valve Check

Observe the valve's action when energized and de-energized to check operation.

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Water Level Controls Inspection

Inspect and test water level controls (connections) annually during maintenance.

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Safety Valve Failure

A safety valve that doesn't open at the required pressure might be faulty and needs replacement.

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Safety Valve Opening Pressure Range

Safety valves should open between 1.03 and 1.10 MAWP during a pop test (per ASME BPVC).

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Safety Valve Blowdown

ASME BPVC requires blowdown of safety valves to remove sediment.

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Safety Valve Accumulation Test

This test simulates operating conditions to ensure proper opening of the safety valve.

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Safety Valve Accumulation Test Pressure

Maximum acceptable pressure for accumulation test is 1.1 MAWP for 1380 kPa MAWP boilers with a 1310 kPa set safety valve.

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Boiler Flame Failure Detection Test Frequency

Test the system every 30 days, according to ASME CSD-1.

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Flame Failure Simulation

Simulate flame failure to observe the system's response during flame failure testing.

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Gas Burner Thermocouple/Thermopile Test

To test the burner with thermocouple or thermopile sensors close the burner valve.

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Device Testing Procedure

Follow recommended manufacturer's instructions when testing any device.

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Flow Switch Function

Flow switch for copper tubular and fin-tube boilers ensures sufficient water flow during operation.

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Flow Switch Test

Simulate no-flow or low-flow conditions to test the flow switch.

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External Low-Water Cut-off Test

Test the external low-water fuel cut-off by isolating and simulating low water conditions without draining the entire system.

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External Low-Water Cut-off Test Frequency

Test the low water cut-off every 31 days for hot water heating boilers per ASME BPVC VI.

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High-Temperature Cut-off Function

This cut-off system prevents boiler overheating, ensuring safety.

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Study Notes

Gas Burner and Flame Failure Detection

  • Safety shut-off valve should close within recommended time after main burner test firing valve is closed for a gas burner with an interrupted pilot.
  • If ultraviolet scanner fires excessively when exposed to ambient light, adjust scanner or relocate it to reduce exposure.
  • ASME CSD-1 recommends replacing flame rods and scanners every 1-2 years or as specified by manufacturer.

Combustion Control and Safety Shut-down/Lockout

  • Post-purge and safety shut-down/lockout in programmed combustion control prevent fuel leaks and ensure burner safety.
  • Low gas pressure cut-off switch should be tested every 30 days according to ASME CSD-1.
  • To test low gas pressure cut-off during boiler operation, observe gauge or alarm when simulating low gas pressure.

Testing and Maintenance

  • Combustion air proving switches should be tested every 30 days according to ASME CSD-1.
  • Before performing a pop test on safety valves, ensure all relevant safety procedures are followed.
  • Before conducting a manual try lever test for heating boilers in steam service, ensure boiler is in operation and pressure is at minimum.
  • If safety valve continues to simmer during manual try lever test, it may be faulty and should be replaced.
  • Rapidly draining the float chamber in a boiler helps prevent corrosion and sediment buildup.
  • Float chamber blowdown test should be completed every 31 days for power boilers according to ASME CSD-1.
  • Slow drain test should be completed every 366 days for boilers according to ASME CSD-1.

Feedwater Solenoid Valve and Water Level Controls

  • Feedwater solenoid valve operation can be checked by observing valve action when energized and de-energized.
  • Annually, inspect and test water level controls, including connections, as part of maintenance.

Safety Valve Testing and Maintenance

  • If safety valve fails to open at required pressure, it may be faulty and should be replaced.
  • Safety valve should open between 1.03 and 1.10 MAWP during pop test according to ASME BPVC.
  • ASME BPVC requires blowdown of safety valves to prevent accumulation of sediment.
  • Accumulation test for safety valves simulates operating conditions to ensure proper opening.
  • Maximum acceptable pressure during accumulation test is 1.1 MAWP for boilers with a MAWP of 1380 kPa and a safety valve set to 1310 kPa.

Boiler Flame Failure Detection and Testing

  • Boiler flame failure detection systems should be tested every 30 days according to ASME CSD-1.
  • When testing flame failure device, simulate flame failure to observe system reaction.
  • ASME BPVC VI describes recommended procedure for testing flame failure detection systems.

Testing Various Devices

  • To test gas burner with thermocouple or thermopile flame sensor, close burner valve.
  • Follow recommended procedures and manufacturer's instructions when testing various devices.

Flow Switch and Low Water Cut-off

  • Flow switch in copper tubular and copper fin-tube boiler ensures adequate water flow for safe operation.
  • Flow switch can be tested by simulating no-flow or low-flow conditions.
  • External low-water fuel cut-off can be tested without draining entire system by isolating and simulating low-water conditions.
  • ASME BPVC VI recommends testing low water cut-off of hot water heating boilers every 31 days.

High Temperature Cut-off

  • High temperature cut-off in a boiler prevents overheating and ensures safe operation.

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Description

This quiz covers the procedure for testing a boiler safety valve, including recording the opening and closing pressures and steps to take if the valve fails to open at the required pressure.

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