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

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

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

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

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

    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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