Podcast
Questions and Answers
EASY What happens in a furnace when there is a burner management system malfunction?
EASY What happens in a furnace when there is a burner management system malfunction?
- A warning signal is sent to the operator
- The safety shut-off valves open
- The boiler automatically shuts down
- A furnace explosion could occur (correct)
Who should perform the dry run of the burner management system?
Who should perform the dry run of the burner management system?
- Any operator on duty
- An experienced operator or a licensed gas/oil fitter (correct)
- A maintenance technician
- A trainee operator
What happens during the pre-purge period in the dry run?
What happens during the pre-purge period in the dry run?
- Draft fans are at medium speed and air dampers are partially open
- Draft fans are at low speed and air dampers are fully closed
- Draft fans are at high speed and air dampers are fully open (correct)
- Draft fans are off and air dampers are fully closed
What happens during the low fire start period?
What happens during the low fire start period?
What type of water is preferred for the refractory dry-out process?
What type of water is preferred for the refractory dry-out process?
What happens during the pilot trial for ignition period?
What happens during the pilot trial for ignition period?
What happens if the ignition sequence is correct?
What happens if the ignition sequence is correct?
Why is it necessary to dry out new refractory?
Why is it necessary to dry out new refractory?
What is tested during the combustion safeguard test?
What is tested during the combustion safeguard test?
What happens if the boiler is not boiled out?
What happens if the boiler is not boiled out?
What is the purpose of boiling out a new boiler?
What is the purpose of boiling out a new boiler?
What is the purpose of the low water cut-off?
What is the purpose of the low water cut-off?
What is the purpose of the high steam pressure cut-out?
What is the purpose of the high steam pressure cut-out?
What is used to clean the boiler during the boil-out process?
What is used to clean the boiler during the boil-out process?
Why are safety valves tested during the initial firing of a new boiler?
Why are safety valves tested during the initial firing of a new boiler?
What is the purpose of the low water flow cut-off?
What is the purpose of the low water flow cut-off?
What is the purpose of the try lever test?
What is the purpose of the try lever test?
What is done to the drum vent during the refractory dry-out process?
What is done to the drum vent during the refractory dry-out process?
Who should be consulted to assist with the boil-out process?
Who should be consulted to assist with the boil-out process?
What is done to the water level during the refractory dry-out process?
What is done to the water level during the refractory dry-out process?
What is the primary objective of inspecting the boiler internally before startup?
What is the primary objective of inspecting the boiler internally before startup?
What should be checked after maintenance has been done on the water side of a watertube boiler?
What should be checked after maintenance has been done on the water side of a watertube boiler?
Why should some gaskets be coated with a graphite paste?
Why should some gaskets be coated with a graphite paste?
What should be verified before filling the boiler?
What should be verified before filling the boiler?
What should be checked before closing up the boiler?
What should be checked before closing up the boiler?
What is the purpose of inspecting the boiler externally before startup?
What is the purpose of inspecting the boiler externally before startup?
What should be removed before filling the boiler?
What should be removed before filling the boiler?
Why is careful gasket installation important?
Why is careful gasket installation important?
What is the purpose of the low oil pressure cut-off switch in boilers fired on fuel oil?
What is the purpose of the low oil pressure cut-off switch in boilers fired on fuel oil?
What is the function of the combustion air proving switch in mechanical draft boilers?
What is the function of the combustion air proving switch in mechanical draft boilers?
What is the purpose of the low atomizing media pressure cut-off switch in boilers fired on fuel oil?
What is the purpose of the low atomizing media pressure cut-off switch in boilers fired on fuel oil?
What is the function of the flame safeguard?
What is the function of the flame safeguard?
What happens when the low oil pressure cut-off switch is activated?
What happens when the low oil pressure cut-off switch is activated?
Where can you find more information about the function, construction, and purpose of boiler safety devices and burner management systems?
Where can you find more information about the function, construction, and purpose of boiler safety devices and burner management systems?
What is the primary objective of inspecting the boiler internally before startup?
What is the primary objective of inspecting the boiler internally before startup?
What is the primary function of the combustion air proving switch in mechanical draft boilers?
What is the primary function of the combustion air proving switch in mechanical draft boilers?
Why is it necessary to remove all debris from the boiler after furnace refractory work?
Why is it necessary to remove all debris from the boiler after furnace refractory work?
What is the purpose of coating some gaskets with graphite paste?
What is the purpose of coating some gaskets with graphite paste?
What happens when the low atomizing media pressure cut-off switch is activated in a boiler fired on fuel oil?
What happens when the low atomizing media pressure cut-off switch is activated in a boiler fired on fuel oil?
What is the purpose of the flame safeguard in a boiler?
What is the purpose of the flame safeguard in a boiler?
What should be verified before filling the boiler with water?
What should be verified before filling the boiler with water?
Why is careful gasket installation important?
Why is careful gasket installation important?
What is the function of the low oil pressure cut-off switch in a boiler fired on fuel oil?
What is the function of the low oil pressure cut-off switch in a boiler fired on fuel oil?
What happens when the combustion air proving switch is activated in a mechanical draft boiler?
What happens when the combustion air proving switch is activated in a mechanical draft boiler?
What should be checked after maintenance has been done on the water side of a watertube boiler?
What should be checked after maintenance has been done on the water side of a watertube boiler?
MEDIUM What should be checked before closing up the boiler?
MEDIUM What should be checked before closing up the boiler?
What is the purpose of the low atomizing media pressure cut-off switch in a boiler fired on fuel oil?
What is the purpose of the low atomizing media pressure cut-off switch in a boiler fired on fuel oil?
What should be removed before filling the boiler with water?
What should be removed before filling the boiler with water?
What is the primary purpose of drying out new refractory in a furnace?
What is the primary purpose of drying out new refractory in a furnace?
Why is it necessary to boil out a new boiler?
Why is it necessary to boil out a new boiler?
What should be done to the drum vent during the refractory dry-out process?
What should be done to the drum vent during the refractory dry-out process?
What is used to clean the boiler during the boil-out process?
What is used to clean the boiler during the boil-out process?
Why are safety valves tested during the initial firing of a new boiler?
Why are safety valves tested during the initial firing of a new boiler?
What is the potential consequence of a burner management system malfunction?
What is the potential consequence of a burner management system malfunction?
Who should perform the dry run of the burner management system?
Who should perform the dry run of the burner management system?
What type of water is preferred for the refractory dry-out process?
What type of water is preferred for the refractory dry-out process?
What is the purpose of shutting the main burner and pilot burner test firing valves during the dry run?
What is the purpose of shutting the main burner and pilot burner test firing valves during the dry run?
What should be done to the water level during the refractory dry-out process?
What should be done to the water level during the refractory dry-out process?
Who should be consulted to assist with the boil-out process?
Who should be consulted to assist with the boil-out process?
What happens during the low fire start period in the dry run?
What happens during the low fire start period in the dry run?
What is tested during the combustion safeguard test?
What is tested during the combustion safeguard test?
What device monitors for safe operating conditions during boiler operation?
What device monitors for safe operating conditions during boiler operation?
What is the purpose of the high steam pressure cut-out?
What is the purpose of the high steam pressure cut-out?
Why is it necessary to purge the furnace before starting the boiler?
Why is it necessary to purge the furnace before starting the boiler?
What is tested during the combustion safeguard test?
What is tested during the combustion safeguard test?
What happens when the low gas pressure cut-off switch is activated?
What happens when the low gas pressure cut-off switch is activated?
What is the purpose of the low water flow cut-off?
What is the purpose of the low water flow cut-off?
What is the purpose of testing safety devices?
What is the purpose of testing safety devices?
What is the primary objective of internally inspecting the boiler before startup?
What is the primary objective of internally inspecting the boiler before startup?
Why is it necessary to remove all debris from the boiler after furnace refractory work?
Why is it necessary to remove all debris from the boiler after furnace refractory work?
What is the purpose of coating some gaskets with graphite paste?
What is the purpose of coating some gaskets with graphite paste?
What should be checked before filling the boiler with water?
What should be checked before filling the boiler with water?
What is the primary function of the low oil pressure cut-off switch in boilers fired on fuel oil?
What is the primary function of the low oil pressure cut-off switch in boilers fired on fuel oil?
What is the purpose of the combustion air proving switch in mechanical draft boilers?
What is the purpose of the combustion air proving switch in mechanical draft boilers?
What is the importance of ensuring that all tools taken into the boiler are checked off as removed?
What is the importance of ensuring that all tools taken into the boiler are checked off as removed?
Why is careful gasket installation important?
Why is careful gasket installation important?
What happens when the flame safeguard is activated?
What happens when the flame safeguard is activated?
What is the primary function of the low atomizing media pressure cut-off switch in boilers fired on fuel oil?
What is the primary function of the low atomizing media pressure cut-off switch in boilers fired on fuel oil?
What should be verified before closing up the boiler?
What should be verified before closing up the boiler?
Where can you find more information about the function, construction, and purpose of boiler safety devices and burner management systems?
Where can you find more information about the function, construction, and purpose of boiler safety devices and burner management systems?
What should be removed before filling the boiler with water?
What should be removed before filling the boiler with water?
What is the primary purpose of the tests described in Part B, Unit 4, Chapter 4?
What is the primary purpose of the tests described in Part B, Unit 4, Chapter 4?
What is the primary reason for slowly drying out new refractory in a furnace?
What is the primary reason for slowly drying out new refractory in a furnace?
What is the purpose of leaving a drum vent open during the refractory dry-out process?
What is the purpose of leaving a drum vent open during the refractory dry-out process?
What is the consequence of not boiling out a new boiler?
What is the consequence of not boiling out a new boiler?
What is the purpose of the try lever test and the pop test during the initial firing of a new boiler?
What is the purpose of the try lever test and the pop test during the initial firing of a new boiler?
What is the purpose of consulting a refractory specialist during the refractory dry-out process?
What is the purpose of consulting a refractory specialist during the refractory dry-out process?
What is the purpose of the combustion safeguard controls test?
What is the purpose of the combustion safeguard controls test?
What is the purpose of adding detergent type chemicals to the boiler water during the boil-out process?
What is the purpose of adding detergent type chemicals to the boiler water during the boil-out process?
Why is it necessary to maintain the water level during the refractory dry-out process?
Why is it necessary to maintain the water level during the refractory dry-out process?
What is the purpose of the boiler boil-out process?
What is the purpose of the boiler boil-out process?
What is the primary purpose of performing a dry run on a mechanical draft boiler?
What is the primary purpose of performing a dry run on a mechanical draft boiler?
What is the consequence of not testing the safety valves during the initial firing of a new boiler?
What is the consequence of not testing the safety valves during the initial firing of a new boiler?
What happens when the ignition sequence is correct during the dry run?
What happens when the ignition sequence is correct during the dry run?
What is the purpose of testing the low water cut-off device?
What is the purpose of testing the low water cut-off device?
What is the purpose of testing the high steam pressure cut-out device?
What is the purpose of testing the high steam pressure cut-out device?
Why is it necessary to test the safety devices during the initial firing of a new boiler?
Why is it necessary to test the safety devices during the initial firing of a new boiler?
What is the purpose of the pilot trial for ignition period during the dry run?
What is the purpose of the pilot trial for ignition period during the dry run?
What happens during the post-purge period in the dry run?
What happens during the post-purge period in the dry run?
What is the purpose of the combustion safeguard test?
What is the purpose of the combustion safeguard test?
What happens when the low gas pressure cut-off switch is activated?
What happens when the low gas pressure cut-off switch is activated?
What is the purpose of the flame safeguard?
What is the purpose of the flame safeguard?
Match the following boiler safety devices with their functions:
Match the following boiler safety devices with their functions:
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Match the following tests with their corresponding purposes:
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Match the following steps with their corresponding purposes:
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Match the following terms with their corresponding purposes:
Match the following actions with their corresponding purposes:
Match the following actions with their corresponding purposes:
Match the following terms with their corresponding explanations:
Match the following terms with their corresponding explanations:
Match the following boiler components with their functions:
Match the following boiler components with their functions:
Match the following boiler preparation steps with their purposes:
Match the following boiler preparation steps with their purposes:
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Match the following boiler components with their maintenance requirements:
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Study Notes
Boiler Startup and Safety
Boiler Proper
- Inspect the boiler internally and externally before closing it up to ensure it's free from scale, oil, tools, debris, and other foreign material.
- Check internal baffles to confirm they are secure, especially if they are steam drum internals.
- Verify that all tools taken into the boiler are removed to prevent anything from falling into a water tube.
- Ensure burners are clean and ready for firing, and soot blowers are properly aligned and move freely.
- Use new handhole and manhole gaskets, and follow the manufacturer's recommendations for gasket coating and torque specifications.
- Ensure all work permits have been surrendered, and all lockout tags have been removed.
Refractory Dry-Out
- If new refractory has been installed in the furnace, slowly dry it out before raising the furnace to normal operating temperature to prevent damage.
- Fire the boiler at the lowest firing rate, and then turn it off for a period of time to allow the refractory to cure.
- Consult a refractory specialist to determine the best method of drying the refractory.
- Fill the boiler to the normal level with soft, chemically treated, and deaerated water before starting the dry-out.
- Leave a drum vent open to prevent pressure buildup while the boiler is firing.
Boiler Boil Out
- Perform a boil-out on a new boiler to remove grease, welding debris, dirt, and oil from construction.
- Add detergent-type chemicals to the boiler water, heat the water, and then periodically blow down to dislodge dirt and remove sludge.
- Use alkaline solutions such as soda ash, caustic soda, trisodium phosphate, and sodium silicate.
- Consult an experienced water treatment specialist to assist with the boil-out.
Safety and Controls
- Test safety devices and control systems during the initial firing of a new boiler or one that is coming out of an extended outage.
- Verify the operation of safety valves, combustion controls, and operating controls.
Safety Valves
- Test safety valves when firing a boiler for the first time or when bringing a boiler back online after a maintenance outage.
- Perform a try lever test and a pop test to verify operation of each safety valve.
Combustion Safeguard Controls
- Test combustion controls before the boiler is initially fired or if it has been out of service for a prolonged period.
- Perform a dry run to ensure that fan dampers, fan speeds, firing rate control valves, safety shut-off valves, ignition transformer, airflow proving switches, flame sensors, and fuel pressure cut-off switches operate correctly.
- Follow the manufacturer's procedures for the dry run.
Safety Devices
- Test safety devices to monitor for safe operating conditions during boiler operation, including:
- Low water cut-off
- High steam pressure cut-out
- High water temperature cut-out
- Low water flow cut-off
- High and low gas pressure cut-offs
- Low oil pressure cut-off switch
- Combustion air proving switch
- Low atomizing media pressure cut-off switch
- Flame safeguard
Boiler Startup and Safety
Boiler Proper
- Inspect the boiler internally and externally before closing it up to ensure it's free from scale, oil, tools, debris, and other foreign material.
- Check internal baffles to confirm they are secure, especially if they are steam drum internals.
- Verify that all tools taken into the boiler are removed to prevent anything from falling into a water tube.
- Ensure burners are clean and ready for firing, and soot blowers are properly aligned and move freely.
- Use new handhole and manhole gaskets, and follow the manufacturer's recommendations for gasket coating and torque specifications.
- Ensure all work permits have been surrendered, and all lockout tags have been removed.
Refractory Dry-Out
- If new refractory has been installed in the furnace, slowly dry it out before raising the furnace to normal operating temperature to prevent damage.
- Fire the boiler at the lowest firing rate, and then turn it off for a period of time to allow the refractory to cure.
- Consult a refractory specialist to determine the best method of drying the refractory.
- Fill the boiler to the normal level with soft, chemically treated, and deaerated water before starting the dry-out.
- Leave a drum vent open to prevent pressure buildup while the boiler is firing.
Boiler Boil Out
- Perform a boil-out on a new boiler to remove grease, welding debris, dirt, and oil from construction.
- Add detergent-type chemicals to the boiler water, heat the water, and then periodically blow down to dislodge dirt and remove sludge.
- Use alkaline solutions such as soda ash, caustic soda, trisodium phosphate, and sodium silicate.
- Consult an experienced water treatment specialist to assist with the boil-out.
Safety and Controls
- Test safety devices and control systems during the initial firing of a new boiler or one that is coming out of an extended outage.
- Verify the operation of safety valves, combustion controls, and operating controls.
Safety Valves
- Test safety valves when firing a boiler for the first time or when bringing a boiler back online after a maintenance outage.
- Perform a try lever test and a pop test to verify operation of each safety valve.
Combustion Safeguard Controls
- Test combustion controls before the boiler is initially fired or if it has been out of service for a prolonged period.
- Perform a dry run to ensure that fan dampers, fan speeds, firing rate control valves, safety shut-off valves, ignition transformer, airflow proving switches, flame sensors, and fuel pressure cut-off switches operate correctly.
- Follow the manufacturer's procedures for the dry run.
Safety Devices
- Test safety devices to monitor for safe operating conditions during boiler operation, including:
- Low water cut-off
- High steam pressure cut-out
- High water temperature cut-out
- Low water flow cut-off
- High and low gas pressure cut-offs
- Low oil pressure cut-off switch
- Combustion air proving switch
- Low atomizing media pressure cut-off switch
- Flame safeguard
Boiler Startup and Safety
Boiler Proper
- Inspect the boiler internally and externally before closing it up to ensure it's free from scale, oil, tools, debris, and other foreign material.
- Check internal baffles to confirm they are secure, especially if they are steam drum internals.
- Verify that all tools taken into the boiler are removed to prevent anything from falling into a water tube.
- Ensure burners are clean and ready for firing, and soot blowers are properly aligned and move freely.
- Use new handhole and manhole gaskets, and follow the manufacturer's recommendations for gasket coating and torque specifications.
- Ensure all work permits have been surrendered, and all lockout tags have been removed.
Refractory Dry-Out
- If new refractory has been installed in the furnace, slowly dry it out before raising the furnace to normal operating temperature to prevent damage.
- Fire the boiler at the lowest firing rate, and then turn it off for a period of time to allow the refractory to cure.
- Consult a refractory specialist to determine the best method of drying the refractory.
- Fill the boiler to the normal level with soft, chemically treated, and deaerated water before starting the dry-out.
- Leave a drum vent open to prevent pressure buildup while the boiler is firing.
Boiler Boil Out
- Perform a boil-out on a new boiler to remove grease, welding debris, dirt, and oil from construction.
- Add detergent-type chemicals to the boiler water, heat the water, and then periodically blow down to dislodge dirt and remove sludge.
- Use alkaline solutions such as soda ash, caustic soda, trisodium phosphate, and sodium silicate.
- Consult an experienced water treatment specialist to assist with the boil-out.
Safety and Controls
- Test safety devices and control systems during the initial firing of a new boiler or one that is coming out of an extended outage.
- Verify the operation of safety valves, combustion controls, and operating controls.
Safety Valves
- Test safety valves when firing a boiler for the first time or when bringing a boiler back online after a maintenance outage.
- Perform a try lever test and a pop test to verify operation of each safety valve.
Combustion Safeguard Controls
- Test combustion controls before the boiler is initially fired or if it has been out of service for a prolonged period.
- Perform a dry run to ensure that fan dampers, fan speeds, firing rate control valves, safety shut-off valves, ignition transformer, airflow proving switches, flame sensors, and fuel pressure cut-off switches operate correctly.
- Follow the manufacturer's procedures for the dry run.
Safety Devices
- Test safety devices to monitor for safe operating conditions during boiler operation, including:
- Low water cut-off
- High steam pressure cut-out
- High water temperature cut-out
- Low water flow cut-off
- High and low gas pressure cut-offs
- Low oil pressure cut-off switch
- Combustion air proving switch
- Low atomizing media pressure cut-off switch
- Flame safeguard
Boiler Startup and Safety
Boiler Proper
- Inspect the boiler internally and externally before closing it up to ensure it's free from scale, oil, tools, debris, and other foreign material.
- Check internal baffles to confirm they are secure, especially if they are steam drum internals.
- Verify that all tools taken into the boiler are removed to prevent anything from falling into a water tube.
- Ensure burners are clean and ready for firing, and soot blowers are properly aligned and move freely.
- Use new handhole and manhole gaskets, and follow the manufacturer's recommendations for gasket coating and torque specifications.
- Ensure all work permits have been surrendered, and all lockout tags have been removed.
Refractory Dry-Out
- If new refractory has been installed in the furnace, slowly dry it out before raising the furnace to normal operating temperature to prevent damage.
- Fire the boiler at the lowest firing rate, and then turn it off for a period of time to allow the refractory to cure.
- Consult a refractory specialist to determine the best method of drying the refractory.
- Fill the boiler to the normal level with soft, chemically treated, and deaerated water before starting the dry-out.
- Leave a drum vent open to prevent pressure buildup while the boiler is firing.
Boiler Boil Out
- Perform a boil-out on a new boiler to remove grease, welding debris, dirt, and oil from construction.
- Add detergent-type chemicals to the boiler water, heat the water, and then periodically blow down to dislodge dirt and remove sludge.
- Use alkaline solutions such as soda ash, caustic soda, trisodium phosphate, and sodium silicate.
- Consult an experienced water treatment specialist to assist with the boil-out.
Safety and Controls
- Test safety devices and control systems during the initial firing of a new boiler or one that is coming out of an extended outage.
- Verify the operation of safety valves, combustion controls, and operating controls.
Safety Valves
- Test safety valves when firing a boiler for the first time or when bringing a boiler back online after a maintenance outage.
- Perform a try lever test and a pop test to verify operation of each safety valve.
Combustion Safeguard Controls
- Test combustion controls before the boiler is initially fired or if it has been out of service for a prolonged period.
- Perform a dry run to ensure that fan dampers, fan speeds, firing rate control valves, safety shut-off valves, ignition transformer, airflow proving switches, flame sensors, and fuel pressure cut-off switches operate correctly.
- Follow the manufacturer's procedures for the dry run.
Safety Devices
- Test safety devices to monitor for safe operating conditions during boiler operation, including:
- Low water cut-off
- High steam pressure cut-out
- High water temperature cut-out
- Low water flow cut-off
- High and low gas pressure cut-offs
- Low oil pressure cut-off switch
- Combustion air proving switch
- Low atomizing media pressure cut-off switch
- Flame safeguard
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