Term
| What can you do with a Second Class Fireman's License? |
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Definition
| With a Second Class Fireman's License one can operate any boiler or boilers under the engineer of fireman in direct charge there of. |
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Term
| What is the D.P.S.'s definition of a boiler? A pressure vessel? |
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Definition
| A boiler is a closed vessel in which water, under pressure, is transformed into steam by the application of heat. A Pressure Vessel is a closed vessel in which the source of pressure is external to itself. Any pressure vessel not defined as a boiler. |
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Term
| How often must high pressure boilers be inspected in Massachusetts? |
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Definition
| A high pressure boiler must be inspected once each year. The inspections must be internal and external. the external must be performed with the boiler under pressure and the internal with the boiler offline. |
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Term
| What information is on a Certificate of Inspection? |
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Definition
| Name or Owner/User, Location, Size and number of boiler, date of Inspection, Signature of Inspector, M.A.W.P. |
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Term
| How often must air tanks be inspected? |
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Definition
| Compressed air tanks, unless otherwise exempt, over 50PSI must be inspected every two years. |
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Term
| How often must refrigeration equipment be inspected? |
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Definition
| All refrigeration and air conditioning equipment requiring a certificate from the D.P.S. must be inspected at least once a year. |
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Term
| What is a ton of refrigeration? |
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Definition
| The melting of one ton of ice in a 24 hour period. (or 2,000 times the latent heat of fusion which is 144 is 288,000 BTU's per day or 12,00 BTU's/HR) |
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Term
| How does the D.P.S. determine Boiler Horsepower? |
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Definition
| (A.) Manufacturers tag (B.) Steam Output divided by 34.5 (C.) Input BTU's/HR divided by 41,840 (D.) Output BTU's/HR divided by 33475. |
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Term
| How does the D.P.S. determine Turbine Horsepower? |
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Definition
| By the outside diameter of the steam supply line. Does not exceed 1.75 inches less than 9HP. Over 1.75 and does not exceed 3.5 inches = 50HP which is a third class plant. Over 3.5 inches but not greater than 5 inches = 150HP which is a second class plant. Over 5 inches = 150HP which is a first class plant. |
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Term
| Who can appeal the results of an examination by the D.P.S.? |
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Definition
| A person who feels aggrieved by the action of an inspector or inspectors has the right to appeal. |
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Term
| Which boilers require only Periodic Attendance? |
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Definition
| Boilers that have between 9 ans 250 Boiler Horsepower require periodic attendance. |
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Term
| What Boilers Require only Non-Continuous attendance? |
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Definition
| boilers between 251 and 500 Boiler horsepower only Require Non-Continuous attendance. |
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Term
| What boilers require Continuous Attendance? |
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Definition
| Boilers over 501 Boiler Horsepower require continuous attendance. |
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Term
| What is the difference between a gate valve and a globe valve? |
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Definition
| A gate valve is used for on/off services and is not good when used for throttling or changing flow or pressure. A globe valve is used for throttling or changing pressure or flow in a process. |
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Term
| What is a check valve? Where would you find one in a boiler room? |
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Definition
| A check valve is a valve which only allows a fluid to flow in one direction. You would find one on a feed-water line to the boiler after the feed-water pump. |
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Term
| What is a Non-Return valve? Where would you find one? |
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Definition
| A Non-Return valve is a pressure assisted valve which allows steam to only travel in one direction. this valve is normally closed and only is opened when pressure over comes the valves closing pressure. You would normally find one on the steam output of a boiler. |
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Term
| Which boilers require two main steam stop isolation valves? |
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Definition
| When two or more boilers are connected to a common header and the boiler has a manhole. The 2 main steam stops should also have a free blow drain between them. |
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Term
| Name at least 5 safety devices on a boiler. |
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Definition
| Safety Valve, Low Water Cut-out, Flame Scanner, Process Controls, Pressure Gauge, Blow-down Valve, Gauge Glass and Water Column. |
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Term
| What does a Safety Valve do? |
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Definition
| Must discharge all off the steam a boiler can produce without allowing the pressure to rise more than 6% above the M.A.W.P. |
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Term
| how many safety valves are required on a boiler? |
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Definition
| There must be at least one safety valve on a boiler. Boilers with a heating surface over 500 square feet will have two or more. |
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Term
| How often should safety valves be tested? |
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Definition
| A safety valve will be tested on every start up of the boiler. |
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Term
| At what pressure can you manually test the safety valves? |
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Definition
| You can manually test the safety valves at 75% pressure. |
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Term
| The pressure gauge reads 75PSI and the safety valve that is set to blow at 150PSI is blowing. What will you do? |
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Definition
| First replace the pressure gauge, if the problem still exists and the gauge is correct, lift the handle of the safety to try to get it to seal. If the problem still exists, remove the boiler from service and have the valve repaired by a qualified technician or the OEM. |
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Term
| What is saturated steam? What is superheated steam? |
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Definition
| Saturated Steam is steam that has moisture in it. It is the steam that is in the drum and is at the same temperature as the water. Superheated Steam is steam that is removed from the drum and heated again to remove any moisture that may exist. |
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Term
| What is Latent Heat and what is Sensible Heat? |
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Definition
| Latent heat is the heat added to a substance that causes a change in state but not a change in temperature. Sensible heat is heat that is measured with a thermometer. |
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Term
|
Definition
| A B.T.U. us a British Thermal Unit or the amount of heat required to raise 1 pound of water 1 Degree Fahrenheit. |
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Term
| How many BTU's are required to change water at 212°F to steam at 212°F? |
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Definition
| 970.3 BTU's are required. |
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Term
| What is a Gauge Pressure? What is Absolute Pressure? |
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Definition
| Gauge Pressure is the pressure read from a gauge. At atmospheric conditions it will read Zero. Absolute Pressure is the pressure of the surroundings or 14.7PSA. (When reading a gauge glass add 14.7 to what the gauge reads and you will have the PSIA.) |
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Term
| As pressure increases, what happens to the Boiler Point of water? |
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Definition
| The Boiling Point also increases. |
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Term
| As pressure increases what happens to the Latent Heat of Evaporation? |
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Definition
| The Latent Heat of Evaporation increases until 460PSIA and then decreases. |
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Term
| Convert 60°C to Degree's Fahrenheit. |
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Definition
| F=(1.8 X Celsius)+ 32. (1.8 X 60 = 108, Add 32, Total = 140°F) |
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Term
| Convert 90°F to Degree's Celsius. |
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Definition
| C=(F-32)÷1.8 (90-32 = 58, Divide by 1.8, Result = 32.2°C.) |
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Term
| How much pressure will a column of water 10 feet high exert at it's base? |
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Definition
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Term
| What doe the following numbers represent? 970.3, 2.31, .491 and 14.7? |
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Definition
(A.) 970.3 is the amount of BTU's added to convert 1 pound of water at 212°F to steam at 212°F (Latent Heat of Evaporation)
(B.) 2.31 is a column of water with a height of 2.31 feet will exert 1PSI at its base.
(C.) .491 is the conversion fact from inHG to PSI
(D.) 14.7 is atmospheric pressure at sea level. |
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Term
| What is Radiation, Conduction, and Convection? |
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Definition
| Radiation is heat transferred by light waves (i.e. heat from the sun). Conduction is Heat transferred by currents in a fluid (i.e. HRSG heat transfer). Convection is Heat transferred from one molecule to another (i.e. chemical reaction). |
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Term
| What is an economizer? What is an Air Pre-Heater? What is a D.A.? |
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Definition
| an Economizer takes heat from the flue gas and heat from the feed-water to increase boiler efficiency. An Air Pre-Heater takes heat from the boiler flue gas and heats the air which is mixed with the products of combustion to help increase overall boiler efficiency. A Deairator or D.A. is an open water feed heater which mixes steam and feed water. |
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Term
| Name Three things that the D.A. does. |
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Definition
| It acts as a feed-water storage tank, heats feed-water and removes noncondesible gases from the feed-water such as air. |
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Term
| What is a Free-Flowing drain? |
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Definition
| A drain that flows freely so it is visible and not directly into a pipe or vessel. |
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Term
| What does a Super-heater do? |
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Definition
| Takes Super-heater takes saturated steam from the steam drum and heats up the steam until no moisture is present. |
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Term
|
Definition
| A Dry-Pipe ensures that the saturated steam coming from an HRT or Scotch Marine boiler is dry or has no moisture droplets in it. |
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Term
| When should the steam drum vent be opened or closed? |
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Definition
| Should be open on start up until the pressure reaches 25% and closed until shut down when the pressure falls to 25% or below. |
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Term
| Why are Super-Heaters fitted with drains? |
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Definition
| To keep steam flowing through the Super-heater to protect the tubes from overheating and failing on start up or shut down. |
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Term
| What is an Open Feed-Water Heater? A Closed Feed-Water Heater? |
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Definition
| A Open Feed-Water Heater is one that allows water and steam to mix. A Closed Fee-Water Heater does not allow the water and steam to be mixed but allows heat transfer. |
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Term
| What does M.A.W.P. stand for? |
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Definition
| Maximum Allowable Working Pressure. |
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Term
| How many BTU's in 1 Boiler Horsepower? |
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Definition
| 33,475 BTU's in 1 Boiler Horsepower. (970.3 X 34.5) |
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|
Term
|
Definition
| A boiler where the products of combustion are inside the tubes, It was externally fired on coal. |
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Term
| How is an HRT Boiler supported? |
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Definition
| Either it was hung by lugs and rollers or suspended by the refractory. |
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Term
| Which part of an HRT Boiler requires staying? |
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Definition
| The boiler heads require staying. |
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Term
| What is the closing-in line on an HRT Boiler? |
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Definition
| This is where the boiler shell meets the refractory wall. |
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Term
| Why are HRT boilers sloped or angled to the rear head? |
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Definition
| They are sloped or angled to the rear to allow the boiler to be blown down for sediment or water chemistry control. |
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Term
| How can you tell if an HRT Boiler has settled? |
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Definition
| You can tell by the circumference of the blow-down pipe. It is found at the blow-down connection. |
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Term
| What is a reinforcing pad? Where would you find it? |
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Definition
| It is a plate added to the shell of the boiler for better thread penetration. It is found at the blow-off connection. |
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Term
| What is a bag? Where could you find one on an HRT Boiler? |
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Definition
| A Bag is caused by the build up of sediment on the inside of the shell of an HRT Boiler. The bag is formed when the sediment heats up and over time distorts the metal to create a bag like affect on the boiler shell. A Bag can be found on the heating surface of the shell of an HRT Boiler. |
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Term
| How would you calculate the heating surface of an HRT Boiler. |
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Definition
| Parts of the boiler with the products of combustion on one side and water on the other. You would measure the hot gas side parts. The heating surface is usually given in feet squared. |
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Term
| Why would the blow-off pipe be located in the front of an HRT Boiler? |
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Definition
| If the boiler was converted from coal to fuel oil. The oil would be piped in sending the flame further back on the HRT shell. The HRT would then need to be sloped or angled forward and the blow off pipe would then need to come to the front of the HRT as well. |
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Term
| What is the difference between between an HRT and a Scotch Marine Boiler? |
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Definition
| An HRT is externally fired while a Scotch Marine is internally fired. |
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Term
| How much gas passes are in a Scotch Marine boiler? |
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Definition
| A Scotch Marine typically had 3 gas passes. |
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Term
| What is the difference between a Dry-Back and a Wet-Back Scotch Marine Boiler? |
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Definition
| A Wet-Back Scotch Marine Boiler has a leg of water in the back for more heating surface and a Dry-Back did not. |
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Term
| What is a Package Boiler? |
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Definition
| A Package Boiler is a boiler which can easily be transported from site to site. A Package Boiler is usually built completely in a shop and transported to site, hooked up and fired. |
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Term
| How many gas passes in a Package Boiler? |
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Definition
| There are usually 4 gas passes in a typical package boiler. |
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Term
| Describe the water circulation in a Stirling Boiler. |
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Definition
| Water comes into the rear drum, then through a down comber then up the front drum, then to the middle drum and then back to the mud drum. |
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Term
| What does baffling do in a boiler? What would make you believe you have a problem with the baffles? |
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Definition
| Baffles in a boiler direct the flow of combustion gases over the boilers heating surfaces. If you had a high stack temperature you may have a failed baffle plate. |
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Term
| Why are water tubes flared? Why are fire tubes beaded over? |
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Definition
| Water tubes are flared so that they won;t fall out of the boiler. Fire tubes are beaded to keep a water tight seal between the fire tubes and the drum heads. |
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Term
| Name three reasons we need blow-down valves. |
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Definition
| They control chemistry in the boiler by removing sludge and sediment, help control high water levels, drain the boiler for cleaning and inspection, control chemical concentration in the boiler. |
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Term
| How do you blow-down a boiler? |
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Definition
1. Find the true water level.
2. Have 1/2 a gauge glass full or better.
3. Open cooling water to blow-down tank.
4. Open quick opening valve or inside valve
5. Open slow opening or outside valve wide
6. Shut the outside or slow closing valve.
7. Close the inside valve or quick closing valve.
8. Check site glass
9. Secure cooling water to blowdown tank |
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Term
| How do you blow-down a boiler when the gauge glass is not in sight? |
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Definition
| You must use a second person a second person to watch the gauge glass. |
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Term
| How do you find the true Water Level? |
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Definition
1. Slowly open the water column drain wide then close.
2. If the boiler is equipped with a low water cutoff you must disable it.
3. Open the drain on the water glass.
4. Open quick opening valve or inside valve.
5. Open slow opening or outside valve wide.
6. Shut the outside or slow closing valve.
7. Close the inside or quick closing valve.
8. When the level stabilizes check with tri-cocks.
9. Reactivate the low water cut-off. |
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Term
| Explain how you would blow-down a gauge glass. |
|
Definition
1. Open the drain on the water glass.
2. Close the top valve and blow-out the bottom connection.
3. Close the bottom valve and open the top valve to blow-out the top connection.
4. Close the drain valve.
5. Open the top valve.
6. When the level stabilizes check with tri-cocks. |
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Term
| Which safety valve will lift first, drum or super-heater? Why? |
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Definition
| The super-heater safety valve are set to lift first, this is so steam will travel through the super-heater always to keep the tubes from overheating and failing. |
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Term
| What are the controlling factors of single, double, and triple element Feed-Water Regulators? |
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Definition
Single: controlled on water level only.
Double: Senses drum level and steam flow.
Triple: Controls on drum level, Feed-Water Flow and Steam Flow. |
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Term
| Explain the operation of a Thermo-expansion Feed-Water Regulator. |
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Definition
| They work when steam and water occupy a tube that is on a slight incline. As water level drops the steam space inside the tube expands. The expanding tube is connected to a linkage which will open the water valve as more steam occupies the tube than water. |
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Term
| Explain the operation of a Thermo-hydraulic Feed-Water Regulator. |
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Definition
| It works by head pressure. As level goes high, the head pressure of the water and pushes on the diaphragm of the which closes it down sending less water to the drum. Consequently, when more steam occupies the tube, the head the head pressure decreases and releases the diaphragm in the valve allowing it to open more to allow more water flow. |
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Term
| Define Perfect, Complete, and Incomplete combustion. |
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Definition
Perfect: The complete burningof the fuel using a theoretical amount of air with no unused air or fuel. This will give you the hottest flame.
Complete: Completely burning all of the fuel while using excess air.
Incomplete: When not all of the fuel is burned. |
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Term
| What is Primary Air, Secondary Air, and Tertiary Air? |
|
Definition
Primary: Air that is used to control the rate of combustion.
Secondary: Air that is used to increase the efficiency of combustion.
Tertiary: Third source of air entered into combustion usually used for burning solid fuels. |
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Term
| What are the three T's of combustion? |
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Definition
| Time, Temperature, and Turbulence. |
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Term
| What are the Combustibles in Fuel Oil? |
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Definition
| Carbon, Hydrogen, and Sulfur. |
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Term
|
Definition
| The amount of air supplied above the the theoretical air for perfect combustion. |
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|
Term
| What is Balanced Draft, Forced Draft, and Induced Draft? |
|
Definition
Balanced: The use of a forced draft and induced fan together.
Forced: The use of a draft fan forcing outside air into the furnace, which creates a positive pressure on the furnace.
Induced: The use of a fan after the furnace, pushing air up the stack, which creates negative pressure on the furnace. |
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Term
| Name two types of Air Pre-Heaters. |
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Definition
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Term
| What is Draft? How is it measured? |
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Definition
| Draft is the movement of air through a furnace caused by warm air rising due to density. It is measured with a manometer. (U-tube or Inclined Tube) |
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Term
| What is air made up of, by volume and weight? |
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Definition
| Air by volume is made up of 20.91% Oxygen and 79.09 Nitrogen. By weight it is 23.13% Oxygen and 76.85% Nitrogen. |
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Term
| What is Specific Gravity? What is Specific Heat? |
|
Definition
| Specific Gravity is the wight of any substance when compared to the weight of water. Specific Heat is the Amount of Heat required to raise the temperature of one pound of any substance one Degree Fahrenheit. |
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|
Term
| How many Gallons in a Barrel of Oil? |
|
Definition
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|
Term
| What is Smoke? What causes it? |
|
Definition
| Smoke is visible emissions and is caused by incomplete combustion. |
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Term
| Name two means of atomizing fuel oil. |
|
Definition
| 1. Rotary Cup (Mechanical). 2. With High Pressure steam or air. |
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Term
| Why do we purge a Boiler? |
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Definition
| To remove any combustible gases that may still exist in the boiler. |
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Term
| Explain how a Low Water Cut-Out works. |
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Definition
| By sensing the level in a drum usualy by the site glass. When the water reaches a certain level, the low water cut-out will be activated. this device will remove the fires from the boiler as to protect the boiler from overheating due to low or no water in it. |
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Term
| What is Pour Point, Flash Point, and Fire Point. |
|
Definition
Pour: The lowest temperature at which oil will flow.
Flash: Temperature that oil will ignite (with a pop) but will continue to burn.
Fire: Minimum oil temperature which a flame will be sustained for at least 5 seconds. |
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Term
| What would you do if you had a Flame Failure burning Oil. |
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Definition
| Secure the fuel by closing the isolation valves, Purge the furnace and attempt to Re-Lite. During the Purge you can begin to Troubleshoot the cause of the Flame Failure. |
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Term
| What percentages of CO2, O2, CO would you except burning oil. |
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Definition
| Burning oil you would expect 12-14% CO2, 3-5% O2, and 0% CO. |
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Term
| Explain how an Inverted Bucket Trap works. |
|
Definition
| It works by allowing the steam to enter the bucket and make the bucket buoyant. The bucket is in turn attached to a valve and the top of the bucket has a hole in it. As air and water collect they pass through the bucket and into the trap body, the bucket loses buoyancy and the bucket falls opening the valve and releasing the water and air. Once removed, steam will make the bucket buoyant again and the valve will close trapping the steam. |
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Term
| What does a Steam Trap do? |
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Definition
| Removes Air and Water from process steam increasing overall efficiency of the plant without the loss of steam. |
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|
Term
| Name Four types of Steam Traps. |
|
Definition
1. Float type
2. Inverted Bucket
3. Thermostatic
4. Thermodynamic. |
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|
Term
| Explain Steam Injector works. |
|
Definition
| It works by flowing high pressure steam through a nozzle. When the steam exits the nozzle it creates a vacuum. At this point water or a fluid will be picked up by the vacuum and injected into the steam path. |
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Term
| Explain how you would set the valves on a Duplex Pump. |
|
Definition
1. Open the drains and close the steam and exhaust valves to perform LOTO.
2. Find the center of the piston by moving the piston rod all the way to each end making a mark. MEasure the distance between the marks and that will be the center.
3. Plum the rocker arm.
4. Center the valve square over the ports.
5. Equalize for lost motion.
6. Off center the valve.
7. Repeat for other side. |
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|
Term
| What is the difference between a Rotary Pump and a Centrifugal Pump? |
|
Definition
| A Rotary Pump is positive displacement while a Centrifugal Pump is non-positive displacement. |
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|
Term
| What is cavitation? How do you correct cavitation? |
|
Definition
| Cavitation is vapor bubbled in the fluid due to high temperature or low suction head. as these bubbles move towards high pressure areas within the pump the bubbles collapse and fluid rushes to fill the void. One would correct by either lowering the temp of the Feed-Water or lowering the flow the pump to raise suction head. |
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Term
| Explain the procedure for starting a centrifugal pump. |
|
Definition
| Check and open the suction valve. Close the discharge valve. Prime the pump and if necessary vent the casing. Star the pump, when up to operating speed, open the discharge valve slowly. |
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Term
| What do the numbers 10 X 6 X 12 mean in reference to a Duplex Pump. |
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Definition
| 10 is the diameter of the steam valve, 6 is the diameter of the water valve, and 12 is the length of the stroke. |
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Term
| Explain what you would do if the Feed Pump tripped during normal. |
|
Definition
| If a feed pump trips and it is the only one, you attempt to restart it. If you have a standby, you would, knowing that the low water cut-off works, line up the pump and restart it. |
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|
Term
| Where does make-up water come from? |
|
Definition
| From your service water system, which comes from surface water or ground water. |
|
|
Term
| What are the contaminants in make-up water? |
|
Definition
| Suspended Solids, Dissolved Solids and Dissolved Gases. |
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|
Term
| Name two ways two ways to treat Make-Up Water. |
|
Definition
| Internally and Externally. |
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|
Term
| What is Phosphate, Caustic Soda, and Sodium Sulfite used for? |
|
Definition
Phosphate helps prevent scale from forming in the boiler.
Caustic soda which is used to raise the P.H. in a boiler.
Sodium Sulfite which is an Oxygen Scavenger. |
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|
Term
| What is P.H.? How is it measured? |
|
Definition
| P.H. is the measure of a fluid alkalinity or acidity. It is measured on a scale of 0-14 with 7 being neutral. |
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|
Term
| How do we test for Dissolved Solids? |
|
Definition
| By putting an electric charge through the water and measuring its resistance. The better the charge travels, the more the Dissolved solids there are. |
|
|
Term
| Why do we chemically treat condensate return lines? |
|
Definition
| By adding chemicals into the D.A. by means of metering pumps. |
|
|
Term
| How does a Zeolite water softener work? |
|
Definition
| It works by removing hard scale forming ions of calcium and magnesium and exchanges them for sodium ions which are soluable. |
|
|
Term
| Explain how you would replace a broken Gauge Glass. |
|
Definition
1. Isolate the glass by closing the steam and water connections.
2. Open the gauge glass drain.
3. Have proper tools available (wire brush, wrench etc.)
4. If the gauge glass has a protector remove it.
5. Loosen nuts on gauge glass and remove glass and nuts. (wear gloves as the gauge may be hot and glass sharp)
6. Check connections for debris.
7. Wire brush and clean threads on glass connection.
10. Hand tighten the top connection unit.
11. Lift the glass 1/4 inch off the bottom connection and hand tighten the nut.
12. Slowly open the top steam connection to temper the glass.
13. With the top and bottom isolation open, close the drain.
14. If the glass leaks, isolate drain, and tighten up on nuts.
If you need to cut the gauge glass, measure from the top of the outside threads in the top connection to the bottom of the outside threads in the bottom connection and subtract 1.4 inch. |
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