136 Questions
EASY What happens in a furnace when there is a burner management system malfunction?
A furnace explosion could occur
Who should perform the dry run of the burner management system?
An experienced operator or a licensed gas/oil fitter
What happens during the pre-purge period in the dry run?
Draft fans are at high speed and air dampers are fully open
What happens during the low fire start period?
Draft fans are at low speed and air dampers are at minimum position
What type of water is preferred for the refractory dry-out process?
Soft, deaerated, and chemically treated water
What happens during the pilot trial for ignition period?
The ignition transformer is on, and spark is robust, but no pilot flame is observed
What happens if the ignition sequence is correct?
The pilot test firing valve can be opened, and the boiler restarted
Why is it necessary to dry out new refractory?
To prevent damage from trapped water evaporation
What is tested during the combustion safeguard test?
The burner management system's ability to manage the ignition and detect the pilot and main flames
What happens if the boiler is not boiled out?
Major water level control problems may occur
What is the purpose of boiling out a new boiler?
To remove dirt, grease, and oils from construction
What is the purpose of the low water cut-off?
To trip the boiler when the low water condition is detected
What is the purpose of the high steam pressure cut-out?
To trip the boiler when the high steam pressure set point is reached
What is used to clean the boiler during the boil-out process?
Alkaline solutions
Why are safety valves tested during the initial firing of a new boiler?
To ensure the valves are functioning correctly
What is the purpose of the low water flow cut-off?
To trip the boiler when the hot water flow is inadequate
What is the purpose of the try lever test?
To test the safety valves
What is done to the drum vent during the refractory dry-out process?
It is left open to prevent pressure buildup
Who should be consulted to assist with the boil-out process?
An experienced water treatment specialist
What is done to the water level during the refractory dry-out process?
It is maintained by replacing lost water
What is the primary objective of inspecting the boiler internally before startup?
To ensure the boiler is free from oil and debris
What should be checked after maintenance has been done on the water side of a watertube boiler?
Tools taken into the boiler to ensure they have been removed
Why should some gaskets be coated with a graphite paste?
To prevent the gaskets from sticking to the metal
What should be verified before filling the boiler?
The blowoff valves are closed and the vent valve is open
What should be checked before closing up the boiler?
The internal baffles for security
What is the purpose of inspecting the boiler externally before startup?
To ensure the boiler is free from scale and debris
What should be removed before filling the boiler?
The lockout tags
Why is careful gasket installation important?
To prevent dangerous blowouts and costly unplanned boiler outages
What is the purpose of the low oil pressure cut-off switch in boilers fired on fuel oil?
To cause the main fuel safety shut-off valve to close and make the boiler trip
What is the function of the combustion air proving switch in mechanical draft boilers?
To prove the boiler will trip upon loss of a fan
What is the purpose of the low atomizing media pressure cut-off switch in boilers fired on fuel oil?
To prove the boiler will trip upon loss of atomizing air or steam
What is the function of the flame safeguard?
To monitor flame in the boiler furnace
What happens when the low oil pressure cut-off switch is activated?
The main fuel safety shut-off valve will close and the boiler will trip
Where can you find more information about the function, construction, and purpose of boiler safety devices and burner management systems?
Unit 3
What is the primary objective of inspecting the boiler internally before startup?
To check for scale, oil, tools, debris, and other foreign material
What is the primary function of the combustion air proving switch in mechanical draft boilers?
To prove the boiler will trip upon loss of a fan
Why is it necessary to remove all debris from the boiler after furnace refractory work?
To prevent damage to the boiler's internal components
What is the purpose of coating some gaskets with graphite paste?
To make the gasket easier to remove during future maintenance
What happens when the low atomizing media pressure cut-off switch is activated in a boiler fired on fuel oil?
The boiler will trip and the main fuel safety shut-off valve will close
What is the purpose of the flame safeguard in a boiler?
To detect the presence of flame in the boiler furnace
What should be verified before filling the boiler with water?
That the blowoff valves are closed and the vent valve is open
Why is careful gasket installation important?
To prevent costly unplanned boiler outages and dangerous blowouts
What is the function of the low oil pressure cut-off switch in a boiler fired on fuel oil?
To prove the boiler will trip upon loss of fuel oil pressure
What happens when the combustion air proving switch is activated in a mechanical draft boiler?
The boiler will trip and the main fuel safety shut-off valve will close
What should be checked after maintenance has been done on the water side of a watertube boiler?
That all tools taken into the boiler have been removed
MEDIUM What should be checked before closing up the boiler?
That the burners are clean and ready for firing
What is the purpose of the low atomizing media pressure cut-off switch in a boiler fired on fuel oil?
To prove the boiler will trip upon loss of atomizing air or steam
What should be removed before filling the boiler with water?
All tools and debris from the boiler
What is the primary purpose of drying out new refractory in a furnace?
To prevent internal pressure from building up and damaging the refractory
Why is it necessary to boil out a new boiler?
To clean the boiler of grease, dirt, and oils
What should be done to the drum vent during the refractory dry-out process?
Left open to prevent pressure buildup
What is used to clean the boiler during the boil-out process?
Soda ash and other alkaline solutions
Why are safety valves tested during the initial firing of a new boiler?
To ensure they are not faulty
What is the potential consequence of a burner management system malfunction?
Furnace explosion
Who should perform the dry run of the burner management system?
An experienced operator or licensed gas/oil fitter
What type of water is preferred for the refractory dry-out process?
Soft, chemically treated, and deaerated water
What is the purpose of shutting the main burner and pilot burner test firing valves during the dry run?
To prevent delayed fuel ignition and furnace explosion
What should be done to the water level during the refractory dry-out process?
Maintained at a steady level
Who should be consulted to assist with the boil-out process?
An experienced water treatment specialist
What happens during the low fire start period in the dry run?
Draft fans are at low speed, and air dampers are at minimum position
What is tested during the combustion safeguard test?
Combustion controls and operating controls
What device monitors for safe operating conditions during boiler operation?
Safety devices
What is the purpose of the high steam pressure cut-out?
To trip the boiler when the high steam pressure set point is reached
Why is it necessary to purge the furnace before starting the boiler?
To remove air from the furnace
What is tested during the combustion safeguard test?
The burner management system's ability to manage ignition and detect flames
What happens when the low gas pressure cut-off switch is activated?
The main and pilot safety shut-off valves close, and the boiler trips
What is the purpose of the low water flow cut-off?
To trip the boiler when the water flow is inadequate
What is the purpose of testing safety devices?
To prove that the boiler will trip under unsafe conditions
What is the primary objective of internally inspecting the boiler before startup?
To ensure the boiler is free from scale, oil, tools, debris, and other foreign material
Why is it necessary to remove all debris from the boiler after furnace refractory work?
To ensure all debris has been removed from inside the boiler
What is the purpose of coating some gaskets with graphite paste?
To make them easier to remove the next time the boiler is shut down
What should be checked before filling the boiler with water?
That the blowoff valves are closed, and the vent valve is open
What is the primary function of the low oil pressure cut-off switch in boilers fired on fuel oil?
To prevent fuel valves from opening if there is insufficient oil pressure
What is the purpose of the combustion air proving switch in mechanical draft boilers?
To prevent fuel valves from opening if there is insufficient windbox pressure
What is the importance of ensuring that all tools taken into the boiler are checked off as removed?
To ensure nothing has fallen into a water tube
Why is careful gasket installation important?
To prevent dangerous blowouts and costly unplanned boiler outages
What happens when the flame safeguard is activated?
The boiler's fuel valves are closed, and the boiler trips
What is the primary function of the low atomizing media pressure cut-off switch in boilers fired on fuel oil?
To trip the boiler upon loss of atomizing air or steam
What should be verified before closing up the boiler?
That all tools taken into the boiler are checked off as removed
Where can you find more information about the function, construction, and purpose of boiler safety devices and burner management systems?
Unit 3
What should be removed before filling the boiler with water?
All lockout tags
What is the primary purpose of the tests described in Part B, Unit 4, Chapter 4?
To verify the function of boiler safety devices and burner management systems
What is the primary reason for slowly drying out new refractory in a furnace?
To prevent damage to the refractory from trapped water
What is the purpose of leaving a drum vent open during the refractory dry-out process?
To prevent pressure buildup in the boiler
What is the consequence of not boiling out a new boiler?
The boiler will experience major water level control problems
What is the purpose of the try lever test and the pop test during the initial firing of a new boiler?
To test the safety valves and ensure they operate correctly
What is the purpose of consulting a refractory specialist during the refractory dry-out process?
To determine the best method of drying the refractory
What is the purpose of the combustion safeguard controls test?
To test the combustion controls and ensure they operate correctly
What is the purpose of adding detergent type chemicals to the boiler water during the boil-out process?
To clean the boiler and remove grease, welding debris, dirt, and oil
Why is it necessary to maintain the water level during the refractory dry-out process?
To replace water that leaves the drum due to the heating process
What is the purpose of the boiler boil-out process?
To clean the boiler and remove grease, welding debris, dirt, and oil
What is the primary purpose of performing a dry run on a mechanical draft boiler?
To ensure the burner management system operates correctly and safely
What is the consequence of not testing the safety valves during the initial firing of a new boiler?
The boiler will not be able to detect overpressure conditions
What happens when the ignition sequence is correct during the dry run?
The boiler enters a post-purge period
What is the purpose of testing the low water cut-off device?
To prove it will trip the boiler in a low water condition
What is the purpose of testing the high steam pressure cut-out device?
To prove it will trip the boiler when the high steam pressure set point is reached
Why is it necessary to test the safety devices during the initial firing of a new boiler?
To ensure the safety devices function correctly
What is the purpose of the pilot trial for ignition period during the dry run?
To test the ignition transformer and spark
What happens during the post-purge period in the dry run?
The pilot test firing valve is opened
What is the purpose of the combustion safeguard test?
To test the burner management system's ability to manage ignition
What happens when the low gas pressure cut-off switch is activated?
The main burner safety shut-off valve closes
What is the purpose of the flame safeguard?
To detect the pilot and main flames
Match the following boiler safety devices with their functions:
Low oil pressure cut-off switch = Closes the main fuel safety shut-off valve and causes the boiler to trip Combustion air proving switch = Proves the boiler will trip upon loss of fan Low atomizing media pressure cut-off switch = Trips the boiler upon loss of atomizing air or steam Flame safeguard = Monitors for flame in the boiler furnace and closes safety shutoff valves upon loss of flame
Match the following boiler safety devices with their purposes:
Low oil pressure cut-off switch = To prevent fuel valves from opening with low oil pressure Combustion air proving switch = To prove the boiler will trip upon loss of fan Low atomizing media pressure cut-off switch = To trip the boiler upon loss of atomizing air or steam Flame safeguard = To monitor for flame in the boiler furnace
Match the following boiler components with their effects when activated:
Low oil pressure cut-off switch = Causes the boiler to trip and closes the main fuel safety shut-off valve Combustion air proving switch = Causes the boiler to trip upon loss of fan Low atomizing media pressure cut-off switch = Trips the boiler upon loss of atomizing air or steam Flame safeguard = Closes safety shutoff valves and causes the boiler to trip
Match the following boiler safety devices with their locations:
Low oil pressure cut-off switch = Boilers fired on fuel oil Combustion air proving switch = Mechanical draft boilers Low atomizing media pressure cut-off switch = Boilers fired on fuel oil Flame safeguard = Boiler furnace
Match the following boiler safety devices with their permissive functions:
Low oil pressure cut-off switch = Prevents fuel valves from opening with low oil pressure Combustion air proving switch = Prevents fuel valves from opening with insufficient windbox pressure Low atomizing media pressure cut-off switch = Prevents fuel valves from opening with low atomizing media pressure Flame safeguard = Prevents fuel valves from opening without flame
Match the following boiler safety devices with their tests:
Low oil pressure cut-off switch = Proves the boiler will trip upon low oil pressure Combustion air proving switch = Proves the boiler will trip upon loss of fan Low atomizing media pressure cut-off switch = Proves the boiler will trip upon loss of atomizing air or steam Flame safeguard = Proves the boiler will trip upon loss of flame
Match the following safety devices with their functions:
Low water cut-off = Trips the boiler in a low water condition High steam pressure cut-out = Trips the boiler when the high steam pressure set point is reached Low water flow cut-off = Trips the boiler when the hot water flow is inadequate High gas pressure cut-off = Trips the boiler when the high gas pressure set point is reached
Match the following steps with their corresponding periods in the dry run procedure:
Draft fans are at high speed = Pre-purge period Ignition transformer on, and spark is robust = Pilot trial for ignition period Air dampers are at minimum position = Low fire start period Pilot flame is established = Post-purge period
Match the following tests with their purposes:
Combustion safeguard test = Tests the burner management system's ability to manage ignition Low water cut-off test = Tests the low water cut-off device High steam pressure cut-out test = Tests the high steam pressure cut-out device Low gas pressure cut-off test = Tests the low gas pressure cut-off device
Match the following terms with their corresponding purposes:
Refractory Dry-Out = To remove grease, welding debris, dirt, and oil from the boiler Boiler Boil Out = To slowly dry out new refractory in the furnace Safety Valves = To test the combustion controls before firing the boiler Combustion Safeguard Controls = To prevent damage to new refractory by slowly raising the furnace temperature
Match the following devices with their functions:
Flame safeguard = Monitors the presence of a flame Combustion air proving switch = Proves the presence of combustion air Ignition transformer = Generates a spark for ignition Pilot safety shut-off valve = Cuts off fuel to the pilot burner
Match the following conditions with the corresponding safety devices:
Low water level = Low water cut-off High steam pressure = High steam pressure cut-out Low water flow = Low water flow cut-off High gas pressure = High gas pressure cut-off
Match the following chemicals with their usage:
Soda ash = To clean the boiler during the boil-out process Caustic soda = To dry out new refractory in the furnace Trisodium phosphate = To remove grease and oils from the boiler Sodium silicate = To add alkaline solutions to the boiler water
Match the following actions with the corresponding periods in the dry run procedure:
Shut the main burner and pilot burner test firing valves = Before starting the dry run Observe the operation of the burner management system = During the dry run Open the pilot test firing valve = After the dry run Restart the boiler = After a successful combustion safeguard test
Match the following tests with their corresponding purposes:
Try lever test = To verify the operation of each safety valve on the boiler Pop test = To test the combustion safeguard controls before firing the boiler Safety valve test = To ensure the boiler is clean and free of debris Combustion control test = To ensure the refractory is dry and cured
Match the following actions with their corresponding purposes:
Leaving a drum vent open = To prevent pressure buildup while the boiler is firing Filling the boiler with soft, deaerated, and chemically treated water = To dry out new refractory in the furnace Maintaining the water level = To remove grease and oils from the boiler during boil-out Consulting a refractory specialist = To ensure the boiler is clean and free of debris
Match the following conditions with the corresponding safety devices:
Low atomizing media pressure = Low atomizing media pressure cut-off switch Low oil pressure = Low oil pressure cut-off switch High steam pressure = High steam pressure cut-out Low water level = Low water cut-off
Match the following terms with their corresponding explanations:
Refractory = A type of material used in the furnace Castable refractory = A type of refractory that contains water when newly installed Plastic refractory = A type of refractory that requires slow drying out Boiler boil-out = The process of removing grease and oils from the boiler
Match the following periods with their corresponding descriptions:
Pre-purge period = Draft fans are at high speed and air dampers are fully open Low fire start period = Draft fans are at low speed and air dampers are at minimum position Pilot trial for ignition period = Ignition transformer on, and spark is robust Post-purge period = Pilot flame is established
Match the following safety devices with their corresponding functions:
High steam pressure cut-out = Trips the boiler when the high steam pressure set point is reached Low water flow cut-off = Trips the boiler when the hot water flow is inadequate Low atomizing media pressure cut-off switch = Trips the boiler when the atomizing media pressure is low Flame safeguard = Monitors the presence of a flame
Match the following safety devices with their corresponding purposes:
Safety valves = To prevent damage to new refractory by slowly raising the furnace temperature Combustion safeguard controls = To ensure the boiler is clean and free of debris Low water cut-off = To prevent the boiler from operating with low water levels High steam pressure cut-out = To prevent the boiler from reaching high steam pressure
Match the following tests with their corresponding purposes:
Combustion safeguard test = Tests the burner management system's ability to manage ignition Low water cut-off test = Tests the low water cut-off device High gas pressure cut-off test = Tests the high gas pressure cut-off device Pilot trial for ignition test = Tests the pilot ignition sequence
Match the following steps with their corresponding purposes:
Purging the furnace = To remove air from the furnace before firing the boiler Drying out new refractory = To prevent damage to new refractory by slowly raising the furnace temperature Boiling out the boiler = To remove grease and oils from the boiler Consulting a refractory specialist = To ensure the refractory is dry and cured
Match the following terms with their corresponding purposes:
Furnace = A combustion chamber where fuel is burned to produce steam Refractory dry-out = To slowly dry out new refractory in the furnace Boiler boil-out = To remove grease and oils from the boiler Safety valves = To prevent the boiler from over-pressurizing
Match the following actions with their corresponding purposes:
Firing the boiler at the lowest firing rate = To dry out new refractory in the furnace Leaving a drum vent open = To prevent pressure buildup while the boiler is firing Maintaining the water level = To ensure the boiler is clean and free of debris Consulting a refractory specialist = To ensure the refractory is dry and cured
Match the following terms with their corresponding explanations:
Refractory specialist = An expert who helps dry out new refractory in the furnace Water treatment specialist = An expert who helps clean the boiler during boil-out Safety valve = A device that prevents the boiler from over-pressurizing Combustion safeguard control = A system that ensures the boiler is fired safely
Match the following boiler components with their functions:
Soot blowers = Clean the boiler Burners = Produce heat Manhole gaskets = Seal openings in the boiler Vent valve = Allow air to escape during filling
Match the following boiler preparation steps with their purposes:
Internal inspection = Ensure the boiler is free from debris Gasket coating = Prevent sticking to metal Blowoff valve closure = Prevent water from escaping Lockout tag removal = Allow work to begin
Match the following boiler components with their maintenance requirements:
Furnace refractory = Dry-out process Burners = Firing and ignition testing Water tubes = Cleaning after maintenance Gaskets = Torque specification check
Match the following boiler safety measures with their purposes:
Low water cut-off = Prevent boiler damage High steam pressure cut-out = Prevent explosion Flame safeguard = Prevent uncontrolled ignition Combustion air proving switch = Ensure proper airflow
Match the following boiler startup procedures with their objectives:
Pre-filling checks = Verify vent valve is open Internal inspection = Ensure boiler is clean and clear External inspection = Check for damage or corrosion Gasket installation = Seal all openings securely
Match the following boiler components with their installation requirements:
Gaskets = Coating with graphite paste Burners = Proper alignment and cleaning Soot blowers = Proper alignment and movement Manhole covers = Secure fastening
Match the following boiler preparation steps with their consequences:
Failure to remove debris = Damage to boiler internals Poor gasket installation = Blowouts and unplanned outages Inadequate burner maintenance = Inefficient combustion Incorrect soot blower alignment = Ineffective cleaning
Match the following boiler safety devices with their functions:
Low oil pressure cut-off switch = Shut off fuel oil supply Low atomizing media pressure cut-off switch = Shut off fuel oil supply Flame safeguard = Monitor and control ignition Combustion air proving switch = Ensure proper airflow
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
Learn about the necessary steps and precautions to take when starting a boiler plant for the first time or after a major outage. Understand the importance of inspecting and testing safety and control devices.
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