72 Questions
EASY What is the purpose of maintaining an air cushion in the expansion tank?
To accommodate the expanded water during warmup
When should the stop valve on the boiler outlet be opened?
When the boiler water reaches the temperature of the supply main
What is the recommended procedure when warming up a cold boiler?
Crack open the outlet valve, then slowly open the inlet valve
What should be done after warming up the boiler?
Switch to low fire until sufficiently warmed up
What is the requirement for using the alternative method of warming up a cold boiler?
The on-line boilers have sufficient capacity to heat the extra boiler
Why is it important to plan ahead for heating loads?
To have standby boilers warmed up prior to being required
What is the primary objective of the Power Engineer during the startup of a hot water boiler?
To monitor all aspects of startup
What should be done before starting the boiler?
Prepare the boiler plant auxiliaries according to site-specific procedures
Why is it necessary to wait for at least 5 minutes after shutting the pilot and main gas valves?
To allow the furnace to purge naturally
What is the purpose of the draft fan in some boilers?
To provide a mechanical purge
What is the recommended reference for heating boiler operating practices?
ASME VI Recommended Rules for the Care and Operation of Heating Boilers
What should be done to the boiler control switch before starting the boiler?
Turn it to the 'off' position
What is the purpose of closing the main disconnect switch?
To supply power to the boiler
What should be done if the boiler is equipped with a high-low firing rate control?
Place the boiler on low fire
What should be done with the firing rate control when starting the boiler?
Place the control in manual low fire
What happens after the air damper goes to the low fire position in the ignition sequence?
The electrodes in the igniter spark
Why should the water temperature be raised slowly when starting the boiler?
To avoid overheating the boiler
What should be performed while the boiler is warming up?
Both operating and safety limit checks
What should be checked after the burner shuts down?
Both the water pressure on the tridicator gauge and the water level in the expansion tank
What is the purpose of the try lever and pop tests on the safety relief valve?
To check for evidence of leaking
What is the term used to describe adding a previously non-operating boiler to a system that is already in operation?
Cutting in
What should be done with the valve in the connecting line between the boiler and the expansion tank when cutting in a boiler?
Crack open the valve
Why should the stop valves in the supply and return lines to the boiler be closed during warmup when cutting in a boiler?
To allow the boiler to warm up slowly
MEDIUM What should be entered in the log book after starting the boiler?
The date and time of startup, observed irregularities and corrective actions taken, and other relevant information
What should be performed before starting a hot water boiler?
Preparing the boiler plant auxiliaries according to site-specific procedures
Why is it necessary to wait for at least 5 minutes after shutting the pilot and main gas valves?
To allow the furnace to purge naturally
What should be done if the boiler is equipped with a high-low firing rate control?
Place the boiler on low fire
What should be reviewed before starting a hot water boiler?
The manufacturer recommendations for burner and boiler startup
What is the purpose of closing the main disconnect switch?
To supply power to the boiler
What should be done after shutting the pilot and main gas valves?
Wait for at least 5 minutes to allow the furnace to purge naturally
What should be done with the boiler control switch before starting the boiler?
Place it in the 'off' position
Why should the site-specific standard operating procedures be followed?
Because they are site-specific and necessary for safe boiler operation
What should be done first when starting a boiler?
Turn the boiler control switch to the 'on' or 'start' position
What happens after the pilot ignition trial is over?
The main burner safety shut-off valves open
Why is it important to raise the water temperature slowly?
To prevent leaks in the system
What should be checked frequently while the boiler is warming up?
The burner for leaks
What should be done with the valve in the connecting line between the boiler and the expansion tank when cutting in a boiler?
Crack it open and let the pressure equalize
What should be done with the firing rate control if the boiler is equipped with a fully modulating firing rate control?
Place it in auto
What should be done before increasing the fuel input?
Warming up the boiler and the heating system to normal operating temperature and pressure
What should be performed while the boiler is warming up?
Operating and safety limit checks
What should be entered in the log book after starting the boiler?
All of the above
What is the term used to describe adding a previously non-operating boiler to a system that is already in operation?
Cutting in
Why is it essential to have sufficient space in the expansion tank?
To accommodate the expanded water produced during warmup.
What should be done when the boiler water reaches the temperature of the water in the supply main?
Open the stop valve on the boiler outlet slightly.
What is the alternative method of warming up a cold boiler?
Crack open the outlet valve, then slowly open the inlet valve.
What should be done with the boiler after it has been warmed up?
Switch to 'low fire' or 'automatic' as applicable.
What is the importance of planning ahead for heating loads?
To ensure that standby boilers are warmed up prior to being required.
What is the requirement for using the alternative method of warming up a cold boiler?
The on-line boilers must have sufficient capacity to heat the extra boiler.
What is the primary concern when warming up a cold boiler using the alternative method?
Establishing flow through the boiler without causing shock to the system
What is the purpose of opening the stop valve on the boiler outlet slightly when the boiler water reaches system temperature?
To establish flow through the boiler and prevent shock to the system
Why is it necessary to have standby boilers warmed up prior to being required?
To plan ahead for heating loads and ensure sufficient capacity
What is the primary benefit of maintaining an air cushion in the expansion tank?
To accommodate the expanded water produced during warmup
What is the recommended procedure when the boiler reaches system temperature using the alternative method?
Opening the valve in the return line slowly
What is the primary consideration when using the alternative method of warming up a cold boiler?
Establishing flow through the boiler without causing shock to the system
What is the primary purpose of the 5-minute waiting period after shutting the pilot and main gas valves?
To allow the furnace to purge naturally
Why is it essential to follow the manufacturer's recommendations for burner and boiler startup?
To ensure a safe and proper startup
What should be done with the boiler control switch before starting the boiler?
It should be in the 'off' position
Why is it necessary to review the site-specific standard operating procedures before starting a hot water boiler?
To ensure a safe and efficient startup
What should be done with the main disconnect switch before starting the boiler?
It should be closed to supply power to the boiler
What is the primary purpose of the expansion tank in a hot water boiler system?
To provide a buffer for sudden changes in pressure
Why is it necessary to open the boiler return and supply valves before starting the boiler?
To allow for the circulation of treated water
What should be done with the pilot flame after it has been established?
It should be used to ignition the main burner
What is the correct sequence of events in the ignition sequence of a boiler?
The forced draft fan starts, the air damper fully opens, the boiler purges, the air damper goes to low fire, and the electrodes spark.
What should be done with the valve in the connecting line between the boiler and the expansion tank when cutting in a boiler?
The valve should be cracked open and then fully opened once the pressures equalize.
What should be done with the stop valves in the supply and return lines to the boiler during warmup when cutting in a boiler?
They should be closed.
What should be done with the firing rate control if the boiler is equipped with a fully modulating firing rate control?
It should be placed in auto.
What should be performed while the boiler is warming up?
The operating and safety limit checks should be performed.
What should be done after the burner shuts down?
The water pressure should be checked on the tridicator gauge.
What should be entered in the log book after starting the boiler?
All of the above.
What is the purpose of raising the water temperature slowly when starting the boiler?
To prevent thermal shock to the boiler.
What should be checked frequently while the boiler is warming up?
All of the above.
What is the purpose of the try lever and pop tests on the safety relief valve?
To ensure the valve is functioning properly.
Study Notes
Startup Preparation
- Prepare boiler plant auxiliaries according to site-specific procedures.
- Review manufacturer recommendations for burner and boiler startup.
Boiler Startup Sequence
- Open boiler return and supply valves, if applicable.
- Ensure boiler control switch is in the “off” position.
- Close main disconnect switch to supply power to the boiler.
Furnace Purge and Ignition
- If the boiler has a gas-fired atmospheric burner, allow 5 minutes for natural purge.
- Light the continuous pilot burner according to manufacturer's instructions.
- Open main burner test firing valve.
Main Burner Ignition
- Place boiler on low fire if equipped with high-low firing rate control or manual low fire if equipped with fully modulating firing rate control.
- Turn boiler control switch to the “on” or “start” position.
- Ignition sequence: forced draft fan starts, air damper opens, boiler purges, air damper goes to low fire, electrodes spark, pilot fuel admitted, and main burner ignites.
Warming Up the Boiler
- Raise water temperature slowly, operating the boiler at low fire, until the boiler and heating system reach normal operating temperature and pressure.
- Perform operating and safety limit checks.
Safety Checks
- Check the boiler frequently for leaks and ensure the burner is operating properly.
- Check the safety relief valve for evidence of leaking and perform try lever and pop tests.
Log Book Entry
- Record date and time of startup, observed irregularities, corrective actions taken, time when controls shut off burner, tests performed, and results of tests.
- Include signature of operator.
Cutting in a Boiler
- When adding a previously non-operating boiler to an already operating system, follow the same startup procedures, with exceptions:
- Close the valve in the connecting line between the boiler and the common expansion tank.
- Fill the boiler and raise pressure to at least the minimum required static pressure.
- Crack open the valve and let the pressure equalize, then open the valve fully.
Startup Preparation
- Prepare boiler plant auxiliaries according to site-specific procedures.
- Review manufacturer recommendations for burner and boiler startup.
Boiler Startup Sequence
- Open boiler return and supply valves, if applicable.
- Ensure boiler control switch is in the “off” position.
- Close main disconnect switch to supply power to the boiler.
Furnace Purge and Ignition
- If the boiler has a gas-fired atmospheric burner, allow 5 minutes for natural purge.
- Light the continuous pilot burner according to manufacturer's instructions.
- Open main burner test firing valve.
Main Burner Ignition
- Place boiler on low fire if equipped with high-low firing rate control or manual low fire if equipped with fully modulating firing rate control.
- Turn boiler control switch to the “on” or “start” position.
- Ignition sequence: forced draft fan starts, air damper opens, boiler purges, air damper goes to low fire, electrodes spark, pilot fuel admitted, and main burner ignites.
Warming Up the Boiler
- Raise water temperature slowly, operating the boiler at low fire, until the boiler and heating system reach normal operating temperature and pressure.
- Perform operating and safety limit checks.
Safety Checks
- Check the boiler frequently for leaks and ensure the burner is operating properly.
- Check the safety relief valve for evidence of leaking and perform try lever and pop tests.
Log Book Entry
- Record date and time of startup, observed irregularities, corrective actions taken, time when controls shut off burner, tests performed, and results of tests.
- Include signature of operator.
Cutting in a Boiler
- When adding a previously non-operating boiler to an already operating system, follow the same startup procedures, with exceptions:
- Close the valve in the connecting line between the boiler and the common expansion tank.
- Fill the boiler and raise pressure to at least the minimum required static pressure.
- Crack open the valve and let the pressure equalize, then open the valve fully.
Startup Preparation
- Prepare boiler plant auxiliaries according to site-specific procedures.
- Review manufacturer recommendations for burner and boiler startup.
Boiler Startup Sequence
- Open boiler return and supply valves, if applicable.
- Ensure boiler control switch is in the “off” position.
- Close main disconnect switch to supply power to the boiler.
Furnace Purge and Ignition
- If the boiler has a gas-fired atmospheric burner, allow 5 minutes for natural purge.
- Light the continuous pilot burner according to manufacturer's instructions.
- Open main burner test firing valve.
Main Burner Ignition
- Place boiler on low fire if equipped with high-low firing rate control or manual low fire if equipped with fully modulating firing rate control.
- Turn boiler control switch to the “on” or “start” position.
- Ignition sequence: forced draft fan starts, air damper opens, boiler purges, air damper goes to low fire, electrodes spark, pilot fuel admitted, and main burner ignites.
Warming Up the Boiler
- Raise water temperature slowly, operating the boiler at low fire, until the boiler and heating system reach normal operating temperature and pressure.
- Perform operating and safety limit checks.
Safety Checks
- Check the boiler frequently for leaks and ensure the burner is operating properly.
- Check the safety relief valve for evidence of leaking and perform try lever and pop tests.
Log Book Entry
- Record date and time of startup, observed irregularities, corrective actions taken, time when controls shut off burner, tests performed, and results of tests.
- Include signature of operator.
Cutting in a Boiler
- When adding a previously non-operating boiler to an already operating system, follow the same startup procedures, with exceptions:
- Close the valve in the connecting line between the boiler and the common expansion tank.
- Fill the boiler and raise pressure to at least the minimum required static pressure.
- Crack open the valve and let the pressure equalize, then open the valve fully.
Learn the essential steps for safely starting a hot water boiler, including furnace purge, ignition, and main burner light-off. Understand the importance of following manufacturer operating procedures and site-specific standard operating procedures.
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