Boiler Operator Study Guide - Arkansas

Which valves are located between the boiler and the feedwater pump?

Feedwater Stop Valve and Feedwater Check Valve

What is the function of the Check Valve?

To prevent the boiler pressure from forcing the boiler water back into a feedwater tank or deaerator when the pump shuts off. (Allows flow in only one direction)

The 4 safety features required on a steam boiler is:

Safety Relief Valve, Blow Down Valve, Low Water Cut-off, Pressure Gauge

Safety Relief Valves should be set by a:

Qualified Safety Valve Technician/Firm

Which pressure is considered to be that of a low-pressure boiler?

0-15 PSI-MAWP

What could happen if a steam valve is opened quickly?

Carryover and Priming of the boiler water, causing the boiler water to be siphoned out of the boiler resulting in water hammer to the steam lines and equipment.

No valve of any description shall be placed between the required safety relief valve or valves and the boiler, or on the discharge pipe between the safety valve and the atmosphere! (True or False)

True

A high pressure boiler is one which generates steam or vapor at a pressure of above:

15 PSI

How may the water-gauge glass on a boiler indicate a false water level?

There may be an obstruction(s) in the water gauge fixture, water column, or the piping connecting the column to the boiler proper or the gauge glass valves are closed!

What condition will cause smoke and soot resulting in a loss of heat transfer efficiency and the creation of dangerous carbon monoxide gases?

Incomplete Combustion

What is the purpose of a Refractory Shelf or Baffle Wall in a boiler?

To cause multiple passes in a fire tube boiler for efficiency and to distribute flame evenly in a generation section of a water tube boiler for better heat transfer.

A residue formed in a boiler by adding feedwater chemicals to the boiler water to prevent the scale from forming on the tubes and turn the scale forming salts _______________________?

Into a non-adhering sludge

High pressure steam boilers must be inspected internally and externally at least once each year. The inspection should be made during the same calendar month each year if possible. (True or False)

True

A boiler operator operating a boiler without a license shall be guilty of a misdemeanor and upon conviction thereof shall be punished by a fine of not less than $25 and not more than $100, in addition may be imprisoned for not more than 2 years, or both. (True or False)

True

A boiler operator must have ___________ on-the-job training and pass the State of Arkansas boiler operators examination, before receiving the Arkansas Boilers Operators license.

6 Months

Water boils at what temperature?

212 Degrees F

If you went into a boiler room and the burner was firing, and there was no water visible in the gauge glass, you should immediately add water to the boiler. (True or False)

False

In a fire tube boiler the gases of combustion flow through the tubes and the boiler water _________?

Surrounds the tubes

In a water tube boiler the water passes through the tubes and the fire is on __________?

the outside of the tubes

High Stack Temperature could be an indication of scale or soot? (True or False)

True

A gauge glass allows you to see the water level in the boiler. If the boiler is equipped with only one gauge glass and if that gauge glass is broken and there are no Try Cocks to check the water level...

the boiler is unsafe and must be shutdown until a new gauge glass is installed.

What is the purpose of a Safety Relief Valve on the boiler?

To relieve the boiler pressure and prevent the pressure from exceeding the MAWP of the boiler and thereby preventing a catastrophic explosion.

A measurement of the quantity of heat. The quantity of heat necessary to raise the temperature of one pound of water by 1 F is:

British Thermal Unit (BTU)

A device used to remove condensate from the steam line and heat exchangers preventing water hammer damage?

Steam Trap

A safety relief valve should open when the boiler pressure reaches the MAWP to prevent the boiler from an overpressure condition. (True or False)

True

Combustion that occurs when all the fuel is not burned, resulting in the formation of smoke, soot and carbon monoxide?

Incomplete Combustion

A water pressure test performed on a new boiler or a pressure vessel to ensure its integrity or after repair work to the steam or water side has been accomplished to verify the integrity of the repair is a:

Hydrostatic Test

What device is considered to be the most important safety device on a high pressure steam boiler?

Safety Relief Valve

The pH of the boiler water should be between 8.5 and 11. (True or False)

True

A safety device used to shut off the fuel to the boiler when the water level falls below a safe level is the:

Low Water Cut-off

Water that must be added to the boiler to make up for the water leaving the boiler in the form of steam, leaks in the system, or water that is lost through boiler blowdowns.

Boiler Feedwater

A valve utilized to remove condensate that is trapped between the 2 steam valves on a boiler and to verify the main steam stop valves are not leaking steam. The discharge of this valve must be visible to the operator or inspector while manipulating the valve.

Free Blowing Drain Valve

You should do a manual lift test of the safety relief valve by testing it when the boiler is operating at a pressure of at least 75% the set pressure of the valve. (True or False)

True

The boiler operator should understand how the boiler controls and safety devices operate on a high pressure steam boiler. When in doubt, the operator should check _________?

The manufacturers recommendations or boiler operations manual

The 3 most common fuels for firing boilers are:

Coal, Gas, Oil

A device that uses waste heat from the gases of combustion to heat the feedwater and increase the efficiency of the boiler is:

Economizer

What would cause the water in a gauge glass to fluctuate up and down in an erratic manner?

The boiler water may be high in Total Dissolved Solids (TDS) with a very high conductivity, the boiler water may be contaminated with oils or grease, or a very high chemical concentration due to a malfunctioning chemical feed pump.

Small particles of water carried out with the flow of steam from the boiler and into the main steam line and process equipment is called:

Carryover

High pressure steam boilers, which meet CSD-1 recommendations for local alarms and safety devices, shall be maintained by ___________ attendance by a licensed boiler operator.

Regular

The 3 requirements for combustion are:

Fuel, Heat, Oxygen

Explosions and accidents involving boilers and pressure vessels in the State of Arkansas must be reported to the boiler inspection division within?

24 Hours

The method whereby the boiler water is treated before it enters the boiler to remove scale-forming salts, dissolved oxygen and non-condensable gases.

External Water Treatment

Test that checks the operation of the low water fuel cut off and mimics the loss of a feedwater pump or loss of water going to the boiler and is considered a superior method of testing the low water fuel cut-off is:

Evaporation / Slow Drain Test

Boilers should be fired slowly when first starting up to allow the boiler tubes and shell to warm up and expand uniformly under the action of the increasing temperature and pressure. (True or False)

True

Regardless of the type of fuel being used, before lighting a boiler during a cold start up, the operator must first:

Check for the correct water level

As boiler steam pressure increases, there is a corresponding increase in the:

Steam Temperature and Temperature of the boiler water

Incomplete Combustion can be caused by:

Lack of sufficient air supply to the fuel as it is being burned

With respect to the Arkansas Boiler and Pressure Vessel Law; Any operator found operating a boiler without a state boiler certificate issued by the boiler inspection division, or operating a boiler knowing it to be defective shall:

have his license revoked at once

The 3 types of drafts are:

Induced, Forced, Natural

Burning all of the fuel using only the theoretical amount of air for combustion and is only achievable in a lab is:

Perfect Combustion

Water level carried in the boiler gauge glass during normal operation (approximately one-third to one-half glass)?

NOWL (Normal Operating Water Level)

The maximum operating pressure rating of a boiler or a pressure vessel as determined by the design and construction of the boiler in conformance with ASME Code is:

MAWP (Maximum Allowable Working Pressure)

A form of carryover, whereby, large slugs of water are carried out with the flow of steam from the boiler and into the main steam line and process equipment is called:

Priming

Mechanical draft produced by a fan supplying or forcing air for combustion into the furnace is called:

Forced Draft

A sequence initiated before ignition and after burner shutdown to remove any explosive combustibles and prevent a burner explosion is called the:

Purge Period

The pre-determined pressure at which a safety valve opens and remains open until the pressure drops. Prevents the steam pressure in the boiler from exceeding the MAWP is:

Set Lifting Pressure or Set Popping Pressure

The passing of air through a furnace prior to light-off to remove any fuels or fuel vapors, thereby preventing a furnace explosion is called:

Pre-purge

The passing of air through a furnace after normal burner shutdown?

Post-purge

What determines the size and capacity of a safety relief valve?

The pounds of steam per hour it can discharge at the set lifting pressure.

In the state of Arkansas, a high pressure steam boiler of 50 horsepower and over, and steam boilers used in hospitals, hotels, motels, schools, day cares, nursing homes, theaters, and office buildings must be ___________ by a licensed operator who holds a certificate of competency issued by the boiler inspection division.

under regular attendance

The accumulation of residue produced from impurities in the boiler water is called:

Sludge

A dangerous banging condition that is caused by steam and water mixing in a steam line and will cause damage to pipe, valves, and process equipment is called:

water hammer

Used to refract the heat and protect the metal of the boiler from overheating and is found in boiler doors and components, etc.

Refractory

A device utilized to control the conductivity (Total Dissolved Solids) of the boiler water by skimming the impurities in the boiler water near the surface of the boiler water. Usually located just above the top row of tubes or 3' to 4' below the NOWL is:

Surface Blowdown or Surface Skinner Blowdown

When removing a boiler from service for an extended period of tie the boiler should be:

laid up dry by placing desiccant in both the fire side and the water side. (Can also be laid up dry using a Nitrogen Blanket)

A data sheet used to record pressures, temperatures and other operating conditions of a boiler on a continuous basis is known as a:

Boiler Log

The most common type of feedwater pump utilized to supply the feedwater to a high pressure steam boiler?

Centrifugal feedwater pump

As an average, how many BTU's are present in a cubic foot of Natural Gas?

1,000 BTU's

A device to supply natural gas to the burner at the required volume and pressure needed for proper combustion.

Gas Pressure Regulator

Line coming off the highest part of steam side of the boiler that is used to vent air from the boiler when filling with water and when warming the boiler. (Also used to prevent a vacuum from forming when taking the boiler off-line)

Boiler Vent

The water column and gauge glass on boilers of the horizontal fire tube type shall be set, so that, when the water level is at the lowest reading in the water gauge glass, there shall be at least ________ inches of water over the highest point of the tubes, flues, or crown sheet.

3 Inches

The rapid fluctuations of the boiler water level that can lead to priming or carryover. Caused by impurities and entrained solids on the surface of the boiler water forming a film over the steam bubbles. Causes are oil, fat, grease, faulty boiler chemistry with heavy chemical concentrations.

Foaming

Pump water from the open feedwater heater or deaerator and delivers it to the boiler at the proper pressure and capacity is called a:

Boiler Feedwater Pump

Salts such as calcium carbonate and magnesium carbonate, that when in solution, tend to form a hard, brittle scale on hot surfaces.

Scale-forming Salts

A protective device used on a steam pressure gauge to protect the bourdon tube from high temperature of the steam is a:

Gauge Siphon

Regular attendance, as defined, states the boiler operator must inspect the boiler for proper operation and log the required readings once each hour. Boiler must be equipped with local operating and safety devices and should have local alarm lights and buzzers? (True or False)

True

A safety device used to shut off fuel to the burner in the event the primary low water fuel cut off fails in a low water condition and requires the operator to manually reset the control once the water level in the boiler has been re-established. The control is usually located 3/4' to 1' below the level of primary low water fuel cut off.

Secondary Low Water Cut-off with a Manual Reset

The lowest part of the water side of a water tube boiler, where the bottom blowdown valves are located to conduct the bottom blowdown is called:

Mud Drum

A measure of the ability of electrons to flow through a solution. Utilized to measure the total dissolved solids (TDS) in the boiler water.

Conductivity

A device that detects the invisible infrared light rays produced by the combustion process of the burner that are emitted by both the pilot flame and the main flame?

Flame Scanner

Ancillary equipment used to heat fuel oil to the correct temperature so it can be pumped and burned. The heater can be either steam or electric.

Fuel Oil Heater

Occurs when fuel or combustible gas has built up in the fire side of the boiler. Common causes are leaking fuel valves, failure of combustion air fans, or failure to purge the furnace.

Furnace Explosions

Steel rods (Round or Square) used in boilers to reinforce flat surfaces to prevent bulging. Primarily used to reinforce the flat surfaces of the tubesheets in fire tube boilers.

stays and stay bolts

A type of feedwater heater operating with steam and water in direct contact. The direct contact design will heat the water and mechanically scrub the dissolved oxygen from the feedwater prior to being pumped to the boiler.

Deaerating Feedwater Heater

A pump that delivers the fuel oil to the burner at the proper volume and pressure to atomize and burn the fuel.

Fuel Oil Pump

Installed on boiler main steam lines to allow for the safe expansion and contraction of the steam piping.

Expanding Bends

A measure of the amount of calcium and magnesium salts in the boiler water usually expressed as grains per gallon or parts per million?

Hardness

A tube in a water tube boiler or watewall that maintains circulation in which the water flows downward between the drums or headers?

Downcomer Tube

A burner for firing oil in which the oil is atomized by compressed air which is forced into and through one or more streams of oil, breaking the oil into a fine spray for combustion?

Air-atomizing Oil Burner

Persons, companies, firms, and/or businesses that wish to perform repairs, welding, or alterations on ASME constructed pressure vessels, or within the vessels code boundaries, must have in place a written quality control system acceptable to the department, and have authorization form the National Board to perform such repairs or alterations. In all cases...

The Arkansas Department of Labor, Boiler Inspection Division, must be notified prior to starting repairs or alterations.

Is gauge pressure or absolute pressure used in the ASME Boiler Code for MAWP for a boiler or a pressure vessel?

Gauge Pressure

When a boiler is taken off-line for inspection, the boiler shall be cooled slowly to a temperature that will allow the boiler inspector to safely inspect the boiler without risk of burns. At what point will the boiler be safe to inspect?

When the boiler is cool enough to enter the firebox or furnace and as near ambient temperature as possible.

How often should the boiler operator test the low water fuel cut off on a high pressure steam boiler?

At least once per day or each shift

Why should the water column and the low water fuel cut off chambers be flushed daily by draining the respective devices?

To keep the chambers free of mud and sediment, thus allowing the gauge glass to accurately display the water level, and to test the low water fuel cut-off to make certain it shuts off the burner in the event of a low water condition.

The gauge glass on a horizontal fire tube boiler shows the lowest possible water level in the glass at which the boiler can safely be operated at. How many inches above the tubes should this level be in a fire tube boiler?

3 Inches

The positioning of the gauge glass on water tube boiler can vary according to the manufacture and the design of the water tube boiler. When in doubt of the correct water level, you should?

Consult the manufacturers recommendations for the NOWL

A formal request, in writing, to utilize a remote monitoring system on a high pressure steam boiler must describe the system, the equipment, what is presently installed, and what the plans are for remote monitoring. This formal request, in writing, must be reviewed and shall only be approved by:

The Chief Boiler Inspector

A manually operated remote shutdown switch or circuit breaker located just outside the boiler room and marked for easy identification is called a:

Emergency Shutdown Switch (E-Stop)

A deaerating feedwater heater is used to heat the feedwater prior to being pumped to the boiler to prevent thermal shock and to remove gases from the feedwater to prevent __________ of the tubes.

Oxygen pitting

You discover a safety relief valve on a high pressure steam boiler vented inside the boiler room and not vented to atmosphere. What is the danger?

Should the safety valve lift the steam would scale a person standing near the outlet of the safety relief valve! The steam may also damage equipment, such as electrical, located in the boiler room.