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Questions and Answers
The pressure at the base of a vertical foot of water is:
The pressure at the base of a vertical foot of water is:
- 0.433 psi (correct)
- 0.5 psi
- 1 psi
- 1.5 psi
When performing a hydrostatic test, the pressure on the boiler should be increased to:
When performing a hydrostatic test, the pressure on the boiler should be increased to:
1 ½ times the safety valve setting.
A boiler steam pressure gauge should have a range of:
A boiler steam pressure gauge should have a range of:
1 ½ to 2 times the safety valve setting.
The maximum size of the bottom blowdown line and the surface blowdown line is:
The maximum size of the bottom blowdown line and the surface blowdown line is:
During startup, the boiler vent should remain open until a pressure of:
During startup, the boiler vent should remain open until a pressure of:
No. 6 fuel oil must be heated to reach the required temperature for combustion.
No. 6 fuel oil must be heated to reach the required temperature for combustion.
No. 6 fuel oil must be heated in order to be pumped.
No. 6 fuel oil must be heated in order to be pumped.
Fuel oil heaters must be used when burning:
Fuel oil heaters must be used when burning:
Water weighs approximately:
Water weighs approximately:
In order to burn 1 lb. of fuel, approximately how much air is needed?
In order to burn 1 lb. of fuel, approximately how much air is needed?
A low pressure steam boiler has a maximum allowable working pressure (MAWP) of up to:
A low pressure steam boiler has a maximum allowable working pressure (MAWP) of up to:
A boiler generating 20,000 lb of steam/hr must be supplied with at least:
A boiler generating 20,000 lb of steam/hr must be supplied with at least:
Needed for the combustion of fuel is made up of approximately:
Needed for the combustion of fuel is made up of approximately:
The automatic non-return valve on a boiler being cut in on a line should be opened when the steam pressure on the boiler reaches:
The automatic non-return valve on a boiler being cut in on a line should be opened when the steam pressure on the boiler reaches:
A sudden drop in boiler steam pressure without a corresponding drop in boiler water temperature could result in a boiler explosion.
A sudden drop in boiler steam pressure without a corresponding drop in boiler water temperature could result in a boiler explosion.
Super heater tubes are protected from warping or burning out by:
Super heater tubes are protected from warping or burning out by:
Because of the large volume of water, the boiler most likely to cause a boiler explosion is:
Because of the large volume of water, the boiler most likely to cause a boiler explosion is:
Stays and braces are needed to prevent bulging in:
Stays and braces are needed to prevent bulging in:
After a boiler has had major repair work made on its steam or water side or has developed a low water condition, it should be subjected to:
After a boiler has had major repair work made on its steam or water side or has developed a low water condition, it should be subjected to:
An indication of a dirty fuel oil strainer would be:
An indication of a dirty fuel oil strainer would be:
If air supplied for combustion mixes with gases of combustion, it could lead to a loss of air for combustion and lower boiler efficiency.
If air supplied for combustion mixes with gases of combustion, it could lead to a loss of air for combustion and lower boiler efficiency.
Chemicals added to the boiler water change the scale-forming salts into:
Chemicals added to the boiler water change the scale-forming salts into:
The purpose of a flame failure control is to protect the boiler from:
The purpose of a flame failure control is to protect the boiler from:
To eliminate the danger of a furnace explosion during startup, the firing sequence must first allow for:
To eliminate the danger of a furnace explosion during startup, the firing sequence must first allow for:
A secondary means of determining water level in a boiler are:
A secondary means of determining water level in a boiler are:
The boiler steam-pressure gauge is protected from high temperatures by:
The boiler steam-pressure gauge is protected from high temperatures by:
The rotary cup burner atomizes fuel oil using:
The rotary cup burner atomizes fuel oil using:
Flow meters measure:
Flow meters measure:
The open feed water heater is located:
The open feed water heater is located:
The positioning combustion control system used on older boilers cannot function without air pressure.
The positioning combustion control system used on older boilers cannot function without air pressure.
The air-to-gas ratio is maintained by a(n):
The air-to-gas ratio is maintained by a(n):
Draft is defined as:
Draft is defined as:
On the fuel oil system, the purpose of the duplex strainers on the suction line between the tank and fuel oil pump is:
On the fuel oil system, the purpose of the duplex strainers on the suction line between the tank and fuel oil pump is:
The cold lime-soda process is used to:
The cold lime-soda process is used to:
Safety valve connections must be approved by the American Society of Mechanical Engineers (ASME).
Safety valve connections must be approved by the American Society of Mechanical Engineers (ASME).
An accumulation of combustible gases can cause a furnace explosion.
An accumulation of combustible gases can cause a furnace explosion.
New or re-tubed boilers should be cleaned with:
New or re-tubed boilers should be cleaned with:
An boiler accumulation test is conducted to:
An boiler accumulation test is conducted to:
The underfeed stoker can burn:
The underfeed stoker can burn:
In a water tube boiler, heat and gases of combustion pass:
In a water tube boiler, heat and gases of combustion pass:
A solenoid valve is:
A solenoid valve is:
A fire caused by oil, gas, grease, or paint is classified as:
A fire caused by oil, gas, grease, or paint is classified as:
A balanced draft system is defined as:
A balanced draft system is defined as:
What is extracted from the turbine after it has passed through some of the turbine stages to be used for process work and heating?
What is extracted from the turbine after it has passed through some of the turbine stages to be used for process work and heating?
Test the safety valve on an incoming boiler by hand:
Test the safety valve on an incoming boiler by hand:
Super heater safety valves are set to open before the main safety valves are set to open.
Super heater safety valves are set to open before the main safety valves are set to open.
The induced draft fan is located:
The induced draft fan is located:
A quick-opening valve is used as a bottom blowdown valve:
A quick-opening valve is used as a bottom blowdown valve:
The type of coal most likely to have problems with spontaneous combustion when being stockpiled is:
The type of coal most likely to have problems with spontaneous combustion when being stockpiled is:
Blowdown tanks are used to:
Blowdown tanks are used to:
When testing a safety valve by hand, there must be:
When testing a safety valve by hand, there must be:
Feed water regulator sensing elements are located:
Feed water regulator sensing elements are located:
Draft in the boiler is measured between what two points?
Draft in the boiler is measured between what two points?
Designed to direct the gases of combustion so that they come into close contact with the boiler heating surface are called:
Designed to direct the gases of combustion so that they come into close contact with the boiler heating surface are called:
The boiler vent should be opened when the steam pressure in the boiler has dropped to:
The boiler vent should be opened when the steam pressure in the boiler has dropped to:
Deciding the frequency of blowdown of a boiler is determined by a:
Deciding the frequency of blowdown of a boiler is determined by a:
Cyclone separators are used in:
Cyclone separators are used in:
Larger steam boilers that are equipped with air heaters and/or economizers must use both forced and induced draft fans.
Larger steam boilers that are equipped with air heaters and/or economizers must use both forced and induced draft fans.
The purpose of the scanner is to:
The purpose of the scanner is to:
The scanner must be installed on the front of the boiler to:
The scanner must be installed on the front of the boiler to:
Duplex strainers are found on both the suction and discharge sides of the fuel oil pump.
Duplex strainers are found on both the suction and discharge sides of the fuel oil pump.
A high water level condition in the boiler can be corrected by:
A high water level condition in the boiler can be corrected by:
The heating value of a fuel is expressed in:
The heating value of a fuel is expressed in:
The volume of gas to the burner in a high pressure gas system is controlled by:
The volume of gas to the burner in a high pressure gas system is controlled by:
The low water fuel cutoff control can be tested by:
The low water fuel cutoff control can be tested by:
Pulverized coal has the consistency of talcum powder so that it can come in closer contact with oxygen for complete combustion.
Pulverized coal has the consistency of talcum powder so that it can come in closer contact with oxygen for complete combustion.
Anthracite coal has a high carbon content.
Anthracite coal has a high carbon content.
The Orsat gas analyzer measures the percentage of:
The Orsat gas analyzer measures the percentage of:
A combustible found in fuel includes:
A combustible found in fuel includes:
Small amounts of water that leave the boiler with the steam are called:
Small amounts of water that leave the boiler with the steam are called:
Caustic embrittlement is defined as:
Caustic embrittlement is defined as:
Boiler water having high alkalinity could develop caustic embrittlement.
Boiler water having high alkalinity could develop caustic embrittlement.
Steam separators work on the principle of:
Steam separators work on the principle of:
Regardless of the type of fuel being used, before lighting off a boiler during a cold start-up, the operator must first:
Regardless of the type of fuel being used, before lighting off a boiler during a cold start-up, the operator must first:
The feed water stop valve on the feed water line is located closest to the shell of the boiler so that the:
The feed water stop valve on the feed water line is located closest to the shell of the boiler so that the:
Plant emergency procedures should be established by:
Plant emergency procedures should be established by:
The purpose of the fuel oil return line is:
The purpose of the fuel oil return line is:
The boiler must be cleaned on both the fire and water sides to prepare it for inspection.
The boiler must be cleaned on both the fire and water sides to prepare it for inspection.
The free-blowing drain between the boiler's automatic non-return valve and the main steam stop valve should be closed as soon as the boiler is cut in on the line.
The free-blowing drain between the boiler's automatic non-return valve and the main steam stop valve should be closed as soon as the boiler is cut in on the line.
When a boiler is being inspected, the two main steam stop valves are closed, locked, and tagged.
When a boiler is being inspected, the two main steam stop valves are closed, locked, and tagged.
External feed water treatment conditions the feed water before it enters the boiler and can be a(n):
External feed water treatment conditions the feed water before it enters the boiler and can be a(n):
When all the fuel is burned using the minimal amount of excess air, it is called:
When all the fuel is burned using the minimal amount of excess air, it is called:
Carbon dioxide (CO2) in the flue gas indicates complete combustion.
Carbon dioxide (CO2) in the flue gas indicates complete combustion.
Types of combustion include:
Types of combustion include:
The boiler should be laid up completely dry if there is a danger of the boiler freezing.
The boiler should be laid up completely dry if there is a danger of the boiler freezing.
Steam that has lost its heat and has turned back into water is called:
Steam that has lost its heat and has turned back into water is called:
If the temperature of air entering the heater gets too low, it can cause condensation on the gas side of the air heater.
If the temperature of air entering the heater gets too low, it can cause condensation on the gas side of the air heater.
Maintenance work performed inside a boiler requires a confined space permit that contains procedures to prevent possible injury from hazards.
Maintenance work performed inside a boiler requires a confined space permit that contains procedures to prevent possible injury from hazards.
Closer control of boiler water chemical concentrations is maintained by:
Closer control of boiler water chemical concentrations is maintained by:
The programmer in the ON/OFF control system is used to:
The programmer in the ON/OFF control system is used to:
Steam impinging on boiler tubes would:
Steam impinging on boiler tubes would:
The frequency of blowing down a steam boiler is best ascertained by:
The frequency of blowing down a steam boiler is best ascertained by:
Fuel oil with a low flash point would be dangerous to use.
Fuel oil with a low flash point would be dangerous to use.
The degree of hardness of the coal is referred to as:
The degree of hardness of the coal is referred to as:
Most thermometers used in a steam plant are calibrated in:
Most thermometers used in a steam plant are calibrated in:
A gas pressure regulator is used to control:
A gas pressure regulator is used to control:
The sequence of three numbers found on the data plate attached to a reciprocating feedwater pump indicates the:
The sequence of three numbers found on the data plate attached to a reciprocating feedwater pump indicates the:
Natural draft is produced by:
Natural draft is produced by:
To reduce the heat loss of flue gases going to the chimney, boilers are equipped with:
To reduce the heat loss of flue gases going to the chimney, boilers are equipped with:
If a boiler that was on-line is down because of low steam pressure, the cause is:
If a boiler that was on-line is down because of low steam pressure, the cause is:
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Study Notes
Boiler Pressure and Testing
- Pressure at the base of a vertical foot of water is 0.433 psi.
- Hydrostatic test pressure for the boiler should be increased to 1.5 times the safety valve setting.
- Boiler steam pressure gauges must have a range of 1.5 to 2 times the safety valve setting.
Boiler Operations
- Maximum size for bottom and surface blowdown lines is 2.5 inches.
- During startup, keep the boiler vent open until pressure reaches approximately 3 psi.
- No. 6 fuel oil must be heated both for combustion and to be pumped effectively.
Fuel and Combustion
- Combustion of 1 lb of fuel requires approximately 15 lb of air, which consists of 21% oxygen and 79% nitrogen.
- A dirty fuel oil strainer is indicated by a significant pressure drop across it.
- Complete combustion is signified by the presence of carbon dioxide (CO2) in the flue gas.
Safety and Maintenance
- A low-pressure steam boiler has a maximum allowable working pressure (MAWP) of 15 psi.
- Automatic non-return valves should open when boiler steam pressure reaches 75% to 85% of the line pressure.
- A flame failure control is vital to prevent possible furnace explosions.
Boiler Design and Structure
- Superheater tubes are protected from warping by maintaining a continuous flow of steam.
- Fire tube boilers are most likely to cause explosions due to their large water volume.
- Stays and braces are necessary to prevent bulging in fire tube boilers.
Water and Chemical Management
- Water weighs approximately 8.3 lb/gal.
- Chemicals in boiler water convert scale-forming salts into non-adhering sludge.
- High alkalinity in boiler water can lead to caustic embrittlement, which is cracking along seams and tube ends.
Equipment and Components
- Flow meters measure fluid flow rates.
- Duplex strainers on suction lines allow cleaning without shutting down the boiler.
- A gas pressure regulator maintains desired pressure at the burner and is essential for safe operation.
Combustion Controls
- Air-to-gas ratio is controlled via air dampers and modulating motors.
- The scanner proves the pilot and main flame; its correct installation is vital for safe operation.
- The underfeed stoker can burn anthracite or bituminous coal.
Boiler Efficiency and Operation
- Cyclone separators are used in boilers with superheaters for efficiency.
- Economizers and air heaters reduce heat loss from flue gases.
- Continuous blowdowns help maintain control over boiler water chemical concentrations.
Testing and Inspection
- Regular testing of the safety valve is necessary to ensure operational integrity.
- Boiler inspection requires that main steam stop valves be closed, locked, and tagged.
- The free-blowing drain should be closed immediately after the boiler is cut in on the line for safety.
Emergency and Operational Procedures
- Plant emergency procedures must be established by the chief engineer to ensure safety protocols are followed.
- When preparing a boiler for inspection, both fire and water sides must be cleaned.
- Correct boiler water levels must be checked before lighting off during cold start-up to prevent incidents.
Other Key Points
- The Orsat gas analyzer measures CO2, carbon monoxide, and oxygen in flue gas; useful for assessing combustion efficiency.
- When storing coal, particular attention should be given to bituminous coal due to its spontaneous combustion risk.
- For colder climates, boilers should be laid up dry to prevent freezing damage.
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