4BE3.5 U4 C1 Obj 2 EMH
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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?

  • 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?

  • 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?

    <p>Draft fans are at low speed and air dampers are at minimum position</p> Signup and view all the answers

    What type of water is preferred for the refractory dry-out process?

    <p>Soft, deaerated, and chemically treated water</p> Signup and view all the answers

    What happens during the pilot trial for ignition period?

    <p>The ignition transformer is on, and spark is robust, but no pilot flame is observed</p> Signup and view all the answers

    What happens if the ignition sequence is correct?

    <p>The pilot test firing valve can be opened, and the boiler restarted</p> Signup and view all the answers

    Why is it necessary to dry out new refractory?

    <p>To prevent damage from trapped water evaporation</p> Signup and view all the answers

    What is tested during the combustion safeguard test?

    <p>The burner management system's ability to manage the ignition and detect the pilot and main flames</p> Signup and view all the answers

    What happens if the boiler is not boiled out?

    <p>Major water level control problems may occur</p> Signup and view all the answers

    What is the purpose of boiling out a new boiler?

    <p>To remove dirt, grease, and oils from construction</p> Signup and view all the answers

    What is the purpose of the low water cut-off?

    <p>To trip the boiler when the low water condition is detected</p> Signup and view all the answers

    What is the purpose of the high steam pressure cut-out?

    <p>To trip the boiler when the high steam pressure set point is reached</p> Signup and view all the answers

    What is used to clean the boiler during the boil-out process?

    <p>Alkaline solutions</p> Signup and view all the answers

    Why are safety valves tested during the initial firing of a new boiler?

    <p>To ensure the valves are functioning correctly</p> Signup and view all the answers

    What is the purpose of the low water flow cut-off?

    <p>To trip the boiler when the hot water flow is inadequate</p> Signup and view all the answers

    What is the purpose of the try lever test?

    <p>To test the safety valves</p> Signup and view all the answers

    What is done to the drum vent during the refractory dry-out process?

    <p>It is left open to prevent pressure buildup</p> Signup and view all the answers

    Who should be consulted to assist with the boil-out process?

    <p>An experienced water treatment specialist</p> Signup and view all the answers

    What is done to the water level during the refractory dry-out process?

    <p>It is maintained by replacing lost water</p> Signup and view all the answers

    What is the primary objective of inspecting the boiler internally before startup?

    <p>To ensure the boiler is free from oil and debris</p> Signup and view all the answers

    What should be checked after maintenance has been done on the water side of a watertube boiler?

    <p>Tools taken into the boiler to ensure they have been removed</p> Signup and view all the answers

    Why should some gaskets be coated with a graphite paste?

    <p>To prevent the gaskets from sticking to the metal</p> Signup and view all the answers

    What should be verified before filling the boiler?

    <p>The blowoff valves are closed and the vent valve is open</p> Signup and view all the answers

    What should be checked before closing up the boiler?

    <p>The internal baffles for security</p> Signup and view all the answers

    What is the purpose of inspecting the boiler externally before startup?

    <p>To ensure the boiler is free from scale and debris</p> Signup and view all the answers

    What should be removed before filling the boiler?

    <p>The lockout tags</p> Signup and view all the answers

    Why is careful gasket installation important?

    <p>To prevent dangerous blowouts and costly unplanned boiler outages</p> Signup and view all the answers

    What is the purpose of the low oil pressure cut-off switch in boilers fired on fuel oil?

    <p>To cause the main fuel safety shut-off valve to close and make the boiler trip</p> Signup and view all the answers

    What is the function of the combustion air proving switch in mechanical draft boilers?

    <p>To prove the boiler will trip upon loss of a fan</p> Signup and view all the answers

    What is the purpose of the low atomizing media pressure cut-off switch in boilers fired on fuel oil?

    <p>To prove the boiler will trip upon loss of atomizing air or steam</p> Signup and view all the answers

    What is the function of the flame safeguard?

    <p>To monitor flame in the boiler furnace</p> Signup and view all the answers

    What happens when the low oil pressure cut-off switch is activated?

    <p>The main fuel safety shut-off valve will close and the boiler will trip</p> Signup and view all the answers

    Where can you find more information about the function, construction, and purpose of boiler safety devices and burner management systems?

    <p>Unit 3</p> Signup and view all the answers

    What is the primary objective of inspecting the boiler internally before startup?

    <p>To check for scale, oil, tools, debris, and other foreign material</p> Signup and view all the answers

    What is the primary function of the combustion air proving switch in mechanical draft boilers?

    <p>To prove the boiler will trip upon loss of a fan</p> Signup and view all the answers

    Why is it necessary to remove all debris from the boiler after furnace refractory work?

    <p>To prevent damage to the boiler's internal components</p> Signup and view all the answers

    What is the purpose of coating some gaskets with graphite paste?

    <p>To make the gasket easier to remove during future maintenance</p> Signup and view all the answers

    What happens when the low atomizing media pressure cut-off switch is activated in a boiler fired on fuel oil?

    <p>The boiler will trip and the main fuel safety shut-off valve will close</p> Signup and view all the answers

    What is the purpose of the flame safeguard in a boiler?

    <p>To detect the presence of flame in the boiler furnace</p> Signup and view all the answers

    What should be verified before filling the boiler with water?

    <p>That the blowoff valves are closed and the vent valve is open</p> Signup and view all the answers

    Why is careful gasket installation important?

    <p>To prevent costly unplanned boiler outages and dangerous blowouts</p> Signup and view all the answers

    What is the function of the low oil pressure cut-off switch in a boiler fired on fuel oil?

    <p>To prove the boiler will trip upon loss of fuel oil pressure</p> Signup and view all the answers

    What happens when the combustion air proving switch is activated in a mechanical draft boiler?

    <p>The boiler will trip and the main fuel safety shut-off valve will close</p> Signup and view all the answers

    What should be checked after maintenance has been done on the water side of a watertube boiler?

    <p>That all tools taken into the boiler have been removed</p> Signup and view all the answers

    MEDIUM What should be checked before closing up the boiler?

    <p>That the burners are clean and ready for firing</p> Signup and view all the answers

    What is the purpose of the low atomizing media pressure cut-off switch in a boiler fired on fuel oil?

    <p>To prove the boiler will trip upon loss of atomizing air or steam</p> Signup and view all the answers

    What should be removed before filling the boiler with water?

    <p>All tools and debris from the boiler</p> Signup and view all the answers

    What is the primary purpose of drying out new refractory in a furnace?

    <p>To prevent internal pressure from building up and damaging the refractory</p> Signup and view all the answers

    Why is it necessary to boil out a new boiler?

    <p>To clean the boiler of grease, dirt, and oils</p> Signup and view all the answers

    What should be done to the drum vent during the refractory dry-out process?

    <p>Left open to prevent pressure buildup</p> Signup and view all the answers

    What is used to clean the boiler during the boil-out process?

    <p>Soda ash and other alkaline solutions</p> Signup and view all the answers

    Why are safety valves tested during the initial firing of a new boiler?

    <p>To ensure they are not faulty</p> Signup and view all the answers

    What is the potential consequence of a burner management system malfunction?

    <p>Furnace explosion</p> Signup and view all the answers

    Who should perform the dry run of the burner management system?

    <p>An experienced operator or licensed gas/oil fitter</p> Signup and view all the answers

    What type of water is preferred for the refractory dry-out process?

    <p>Soft, chemically treated, and deaerated water</p> Signup and view all the answers

    What is the purpose of shutting the main burner and pilot burner test firing valves during the dry run?

    <p>To prevent delayed fuel ignition and furnace explosion</p> Signup and view all the answers

    What should be done to the water level during the refractory dry-out process?

    <p>Maintained at a steady level</p> Signup and view all the answers

    Who should be consulted to assist with the boil-out process?

    <p>An experienced water treatment specialist</p> Signup and view all the answers

    What happens during the low fire start period in the dry run?

    <p>Draft fans are at low speed, and air dampers are at minimum position</p> Signup and view all the answers

    What is tested during the combustion safeguard test?

    <p>Combustion controls and operating controls</p> Signup and view all the answers

    What device monitors for safe operating conditions during boiler operation?

    <p>Safety devices</p> Signup and view all the answers

    What is the purpose of the high steam pressure cut-out?

    <p>To trip the boiler when the high steam pressure set point is reached</p> Signup and view all the answers

    Why is it necessary to purge the furnace before starting the boiler?

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

    What is tested during the combustion safeguard test?

    <p>The burner management system's ability to manage ignition and detect flames</p> Signup and view all the answers

    What happens when the low gas pressure cut-off switch is activated?

    <p>The main and pilot safety shut-off valves close, and the boiler trips</p> Signup and view all the answers

    What is the purpose of the low water flow cut-off?

    <p>To trip the boiler when the water flow is inadequate</p> Signup and view all the answers

    What is the purpose of testing safety devices?

    <p>To prove that the boiler will trip under unsafe conditions</p> Signup and view all the answers

    What is the primary objective of internally inspecting the boiler before startup?

    <p>To ensure the boiler is free from scale, oil, tools, debris, and other foreign material</p> Signup and view all the answers

    Why is it necessary to remove all debris from the boiler after furnace refractory work?

    <p>To ensure all debris has been removed from inside the boiler</p> Signup and view all the answers

    What is the purpose of coating some gaskets with graphite paste?

    <p>To make them easier to remove the next time the boiler is shut down</p> Signup and view all the answers

    What should be checked before filling the boiler with water?

    <p>That the blowoff valves are closed, and the vent valve is open</p> Signup and view all the answers

    What is the primary function of the low oil pressure cut-off switch in boilers fired on fuel oil?

    <p>To prevent fuel valves from opening if there is insufficient oil pressure</p> Signup and view all the answers

    What is the purpose of the combustion air proving switch in mechanical draft boilers?

    <p>To prevent fuel valves from opening if there is insufficient windbox pressure</p> Signup and view all the answers

    What is the importance of ensuring that all tools taken into the boiler are checked off as removed?

    <p>To ensure nothing has fallen into a water tube</p> Signup and view all the answers

    Why is careful gasket installation important?

    <p>To prevent dangerous blowouts and costly unplanned boiler outages</p> Signup and view all the answers

    What happens when the flame safeguard is activated?

    <p>The boiler's fuel valves are closed, and the boiler trips</p> Signup and view all the answers

    What is the primary function of the low atomizing media pressure cut-off switch in boilers fired on fuel oil?

    <p>To trip the boiler upon loss of atomizing air or steam</p> Signup and view all the answers

    What should be verified before closing up the boiler?

    <p>That all tools taken into the boiler are checked off as removed</p> Signup and view all the answers

    Where can you find more information about the function, construction, and purpose of boiler safety devices and burner management systems?

    <p>Unit 3</p> Signup and view all the answers

    What should be removed before filling the boiler with water?

    <p>All lockout tags</p> Signup and view all the answers

    What is the primary purpose of the tests described in Part B, Unit 4, Chapter 4?

    <p>To verify the function of boiler safety devices and burner management systems</p> Signup and view all the answers

    What is the primary reason for slowly drying out new refractory in a furnace?

    <p>To prevent damage to the refractory from trapped water</p> Signup and view all the answers

    What is the purpose of leaving a drum vent open during the refractory dry-out process?

    <p>To prevent pressure buildup in the boiler</p> Signup and view all the answers

    What is the consequence of not boiling out a new boiler?

    <p>The boiler will experience major water level control problems</p> Signup and view all the answers

    What is the purpose of the try lever test and the pop test during the initial firing of a new boiler?

    <p>To test the safety valves and ensure they operate correctly</p> Signup and view all the answers

    What is the purpose of consulting a refractory specialist during the refractory dry-out process?

    <p>To determine the best method of drying the refractory</p> Signup and view all the answers

    What is the purpose of the combustion safeguard controls test?

    <p>To test the combustion controls and ensure they operate correctly</p> Signup and view all the answers

    What is the purpose of adding detergent type chemicals to the boiler water during the boil-out process?

    <p>To clean the boiler and remove grease, welding debris, dirt, and oil</p> Signup and view all the answers

    Why is it necessary to maintain the water level during the refractory dry-out process?

    <p>To replace water that leaves the drum due to the heating process</p> Signup and view all the answers

    What is the purpose of the boiler boil-out process?

    <p>To clean the boiler and remove grease, welding debris, dirt, and oil</p> Signup and view all the answers

    What is the primary purpose of performing a dry run on a mechanical draft boiler?

    <p>To ensure the burner management system operates correctly and safely</p> Signup and view all the answers

    What is the consequence of not testing the safety valves during the initial firing of a new boiler?

    <p>The boiler will not be able to detect overpressure conditions</p> Signup and view all the answers

    What happens when the ignition sequence is correct during the dry run?

    <p>The boiler enters a post-purge period</p> Signup and view all the answers

    What is the purpose of testing the low water cut-off device?

    <p>To prove it will trip the boiler in a low water condition</p> Signup and view all the answers

    What is the purpose of testing the high steam pressure cut-out device?

    <p>To prove it will trip the boiler when the high steam pressure set point is reached</p> Signup and view all the answers

    Why is it necessary to test the safety devices during the initial firing of a new boiler?

    <p>To ensure the safety devices function correctly</p> Signup and view all the answers

    What is the purpose of the pilot trial for ignition period during the dry run?

    <p>To test the ignition transformer and spark</p> Signup and view all the answers

    What happens during the post-purge period in the dry run?

    <p>The pilot test firing valve is opened</p> Signup and view all the answers

    What is the purpose of the combustion safeguard test?

    <p>To test the burner management system's ability to manage ignition</p> Signup and view all the answers

    What happens when the low gas pressure cut-off switch is activated?

    <p>The main burner safety shut-off valve closes</p> Signup and view all the answers

    What is the purpose of the flame safeguard?

    <p>To detect the pilot and main flames</p> Signup and view all the answers

    Match the following boiler safety devices with their functions:

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

    Match the following boiler safety devices with their purposes:

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

    Match the following boiler components with their effects when activated:

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

    Match the following boiler safety devices with their locations:

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

    Match the following boiler safety devices with their permissive functions:

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

    Match the following boiler safety devices with their tests:

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

    Match the following safety devices with their functions:

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

    Match the following steps with their corresponding periods in the dry run procedure:

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

    Match the following tests with their purposes:

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

    Match the following terms with their corresponding purposes:

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

    Match the following devices with their functions:

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

    Match the following conditions with the corresponding safety devices:

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

    Match the following chemicals with their usage:

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

    Match the following actions with the corresponding periods in the dry run procedure:

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

    Match the following tests with their corresponding purposes:

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

    Match the following actions with their corresponding purposes:

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

    Match the following conditions with the corresponding safety devices:

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

    Match the following terms with their corresponding explanations:

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

    Match the following periods with their corresponding descriptions:

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

    Match the following safety devices with their corresponding functions:

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

    Match the following safety devices with their corresponding purposes:

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

    Match the following tests with their corresponding purposes:

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

    Match the following steps with their corresponding purposes:

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

    Match the following terms with their corresponding purposes:

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

    Match the following actions with their corresponding purposes:

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

    Match the following terms with their corresponding explanations:

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

    Match the following boiler components with their functions:

    <p>Soot blowers = Clean the boiler Burners = Produce heat Manhole gaskets = Seal openings in the boiler Vent valve = Allow air to escape during filling</p> Signup and view all the answers

    Match the following boiler preparation steps with their purposes:

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

    Match the following boiler components with their maintenance requirements:

    <p>Furnace refractory = Dry-out process Burners = Firing and ignition testing Water tubes = Cleaning after maintenance Gaskets = Torque specification check</p> Signup and view all the answers

    Match the following boiler safety measures with their purposes:

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

    Match the following boiler startup procedures with their objectives:

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

    Match the following boiler components with their installation requirements:

    <p>Gaskets = Coating with graphite paste Burners = Proper alignment and cleaning Soot blowers = Proper alignment and movement Manhole covers = Secure fastening</p> Signup and view all the answers

    Match the following boiler preparation steps with their consequences:

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

    Match the following boiler safety devices with their functions:

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

    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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    Description

    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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