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Gas A Level 2 > Block 2 - Appliance Startup Procedures - Commission Flame Safeguard Systems > Flashcards

Block 2 - Appliance Startup Procedures - Commission Flame Safeguard Systems Flashcards

1
Q

What are the regulatory requirements for gas appliances?

A

Obtain necessary permits, secure product approval, complete field inspections.

Failure to adhere could have serious consequences for your career as an Industrial Gasfitter.

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2
Q

How does Technical Safety BC evaluate applications for product approvals?

A

On a case-by-case basis, requiring certification by a recognized body if a Canadian-recognized standard or other recognized document exists.

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3
Q

What is the first step for non-certified appliances lacking Canadian certification?

A

Apply to register the uncertified gas appliance (Gas Design Registration).

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4
Q

What must be obtained after receiving a journal number for a design?

A

Product Approval permit.

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5
Q

What is required after completing each phase of the gas system authorized by the permit?

A

Request an inspection.

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6
Q

What must be done during commissioning of a gas appliance?

A

A Safety Officer will field certify the unit and affix a decal.

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7
Q

What does the complete Product Approval include?

A

Commissioning permission.

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8
Q

What does section 31 of the Gas Safety Regulations state?

A

A person must not install an appliance unless it displays a certification mark or an approval mark.

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9
Q

What are potential penalties for performing regulated work without a permit?

A

Fines up to $100,000 and/or imprisonment for up to 18 months for individuals; fines up to $200,000 for corporations.

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10
Q

What appliances require mandatory commissioning approval under section 26 (2) of the Gas Safety Regulations?

A

Direct-fired non-recirculating make-up heater, conversion burners, direct-fired equipment, forced draft appliances over 409,600 Btuh.

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11
Q

How much notice must the permit holder give before requesting an assessment?

A

At least 48 hours prior to expected commissioning time.

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12
Q

Who witnesses the testing and commissioning of the appliance?

A

The safety officer.

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13
Q

What should be done if the commissioning approval assessment is waived?

A

Submit a Start Up report to the safety officer.

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14
Q

What should be initiated early in the commissioning process?

A

Communication between the gas fitter of record and the Gas Safety Officer.

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15
Q

What must gas fitters submit to Technical Safety BC after a start-up?

A

A detailed appliance start-up report.

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16
Q

What should the start-up gas fitter information match?

A

The gas fitter of record on the permit application.

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17
Q

What is required for the setup and training of the operator?

A

Manuals and wiring diagrams.

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18
Q

What should be checked during a pre-start-up inspection?

A

Function of gaskets, removal of packing, compliance of valve train, and system connections.

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19
Q

What are some items to check during commissioning?

A
  • Function of gaskets
  • Valve train compliance
  • System connections
  • Electrical terminations
  • Belt and pulley alignment.
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20
Q

What must be confirmed regarding wiring before start-up?

A

Wiring is complete and as per drawings.

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21
Q

What must be checked regarding motor rotation?

A

Correct rotation of 3-phase motors.

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22
Q

How can the rotation of a 3-phase motor be changed?

A

Interchanging any two of the three lines feeding the motor.

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23
Q

What must be done to ensure safety during the commissioning process?

A

Perform a Job Hazard Assessment.

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24
Q

What is the importance of checking every single wiring termination?

A

To prevent system failures due to loose connections.

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25
Q

True or False: Personal locks may be accepted on all industrial sites.

A

False.

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26
Q

Fill in the blank: A complete Product Approval includes _______.

A

[commissioning permission].

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27
Q

What is the primary hazard associated with flame safeguards?

A

Fire or Explosion Hazard. Can cause property damage, severe injury or death.

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28
Q

What must be done before starting tests on flame safeguards?

A

Close all manual fuel shutoff valve(s).

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29
Q

What should be confirmed regarding the flame safeguard model?

A

Confirm that the model is correct and meets all code requirements for the application.

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30
Q

What is necessary regarding grounding when installing a flame safeguard?

A

Confirm that there is a connected dedicated ground wire installed on the subbase.

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31
Q

What should be checked for tightness during installation?

A

Check the tightness of every wiring terminal.

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32
Q

What is the purpose of performing a static checkout?

A

Verify that the subbase is wired correctly, and the external controllers, limits, interlocks, actuators, valves, transformers, motors, and other devices are operating properly.

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33
Q

What is required to complete some of the tests during the static checkout?

A

Gas pressure to the low gas pressure switch, or it needs to be jumped out.

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34
Q

What tools are needed for performing the static checkout?

A

A multi-meter and a pair of 14 AWG jumpers with alligator clips at each end.

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35
Q

Fill in the blank: To perform the Static Checkout, you will need a _______.

A

[multi-meter]

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36
Q

What should be done before opening the main disconnect when adding or removing jumpers?

A

Open the master switch.

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37
Q

What is the first test conducted during the static checkout?

A

Check supply power.

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38
Q

What voltage should be checked between terminals 5 (L1) and L2?

A

Supply power voltage.

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39
Q

What is the second test during the static checkout?

A

Check Limit Circuit.

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40
Q

What should be checked if the voltage reading is abnormal?

A

Check the limit circuit components.

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41
Q

What is the purpose of the lockout interlocks test?

A

Ensure the system locks out correctly when conditions are not met.

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42
Q

What should be observed during the ignition transformer test?

A

You should hear the buzz of the ignition spark.

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43
Q

What should be heard when checking the pilot valve?

A

You should hear the click of the opening of the pilot solenoid valve.

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44
Q

What is tested in tests #6 and #7 during the static checkout?

A

Check Safety Shutoff Valves (SSOV’s).

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45
Q

What should be observed when the main gas valves are opened?

A

Observe the opening of the main gas valves.

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46
Q

What should be done after confirming the mounting base is wired correctly?

A

Reinstall the flame safeguard on the mounting base and proceed to testing.

47
Q

What must be confirmed regarding the sequence of the flame safeguard?

A

You must be familiar with the specific sequencing of the model.

48
Q

What is the purpose of the purge time confirmation?

A

Ensure the purge time is correct for the appliance/application.

49
Q

What happens during the Pilot Trial for Ignition (PTFI) period?

A

Listen for the click of the solenoid opening and buzz of the transformer/spark.

50
Q

What should the flame signal be during the Ultraviolet Ignition Spark Response Test?

A

Flame signal should not be greater than 0.25 Vdc.

51
Q

What indicates a successful pilot flame establishment?

A

A steady, healthy flame signal.

52
Q

What is the maximum flame signal voltage acceptable during testing?

A

5 VDC.

53
Q

What is the minimum flame signal voltage acceptable during testing?

A

1.25 VDC.

54
Q

What must be done to initiate a burner cycle?

A

Close the burner switch.

55
Q

What is the expected outcome of the main burner ignition test?

A

Observe main burner ignition.

56
Q

Fill in the blank: The flame safeguard will lock out at the end of the _______.

A

[Pilot Flame Establishing Period (PFEP)]

57
Q

True or False: The pilot flame will terminate at the end of the Main Flame Establishing Period (MFEP).

A

True.

58
Q

What should be observed when opening the main burner tes fring valve slowly?

A

Main burner ignition

If smooth and rapid, terminate burner cycle and start a third cycle.

59
Q

What is the procedure for testing with an interrupted pilot?

A

Terminate the pilot at the end of the MFEP and lock out the control

Push the reset to start a third cycle.

60
Q

What should be done during the third cycle after the pilot valve is opened?

A

Open the tes fring valve and observe main burner ignition.

61
Q

What should be checked after closing the tes fring valve?

A

Flame failure response time

The flame safeguard should lock out in less than 1 sec.

62
Q

In an intermittent pilot system, what additional action is required?

A

Close the pilot valve also.

63
Q

What is the purpose of the Pilot Turndown Test?

A

To confirm that the smallest recognizable pilot will still light the main burner smoothly.

64
Q

What should be consulted for the initial burner light-off?

A

Burner manufacturer instructions or flame safeguard control instructions.

65
Q

What indicates a faulty UV sensor tube during the test?

A

A reddish glow appears when there is no flame present.

66
Q

What is the significance of the Dynamic Self Check?

A

To confirm that the amplifier is correct.

67
Q

How should the average stable reading be taken during the self-check?

A

Disregard the peaks caused by shutter operation.

68
Q

What happens if there is a continuous signal or no signal during the self-check?

A

The system will lock out.

69
Q

What should be done before putting the burner into service?

A

Check out the installation using the checkout procedures.

70
Q

What is essential to do after completing the checkout procedures?

A

Run the burner through at least one complete cycle.

71
Q

True or False: The system can be put into operation before all checkout tests are completed.

A

False

72
Q

Fill in the blank: The self-check shutter is ______ seconds closed and ______ seconds open.

A

0.4 / 3.6

73
Q

What is the main focus of the lesson regarding gas pressure regulators?

A

Regulator repair and maintenance, specifically for the Fisher LS200 Regulator.

74
Q

What should be done before attempting any maintenance or disassembly of a regulator?

A

Isolate the regulator from system pressure and relieve all internal pressure.

75
Q

How often does Fisher recommend parts replacement for regulators?

A

At a maximum every 10 years.

76
Q

What should be avoided to prevent personal injury during diaphragm casing maintenance?

A

Loosening diaphragm casing cap screws when the control spring has spring force applied.

77
Q

What components should be inspected and potentially replaced during disk or pad maintenance?

A

Disk or pad, O-ring, and locknut.

78
Q

True or False: The balance diaphragm and orifice can be replaced during maintenance.

A

True.

79
Q

What is recommended if a regulator is installed upside down or horizontally?

A

Readjustment is required.

80
Q

What should be done with relief valve O-rings during maintenance?

A

Replace with new ones and lightly lubricate before assembly.

81
Q

What must be done if installing a control spring of a different set pressure range?

A

Remove the set pressure range on the spring case and indicate the new range.

82
Q

What is the standard slope for a sensing line to ensure proper drainage?

A

A ¼” per foot towards the gas piping.

83
Q

What is the primary function of a lubricated plug valve?

A

To control flow by rotating the plug to align a central hole with the downstream direction.

84
Q

What should be done before injecting sealant into a lubricated plug valve?

A

Ensure that the equipment is shut down and automatic shutoff valves are closed.

85
Q

Fill in the blank: A lubricated plug valve consists of a plug and a _______.

A

body.

86
Q

What should be used to coat the adjusting screw during relief valve maintenance?

A

Anti-seize compound.

87
Q

What method is preferred for injecting sealant into a lubricated plug valve?

A

Sealant Gun Service (Using Injection Gun).

88
Q

What should be done if the pressure doesn’t rise during sealant injection?

A

Check if the gun is out of sealant, valve seat is leaking, or packing gland is loose.

89
Q

What is the suggested procedure for testing safety shutoff valves?

A

Perform a valve leak test annually or during PM maintenance.

90
Q

What equipment can be used to measure valve leakage?

A

A 6 mm (0.25 inch) O.D. x 1 mm (0.032 inch) wall tube submerged in water.

91
Q

What should be done if valve testing indicates leakage exceeding 15 bubbles per minute?

A

Perform pre-operational exercising (valve cycling) and retest the valve.

92
Q

What is the first step in the testing procedure for Maxon’s double blocking shut-off valves?

A

Shut down combustion system per manufacturer’s recommended procedure.

93
Q

What should be checked visually before testing shut-off valves?

A

Verify that shut-off valves #1 and #2 are closed.

94
Q

True or False: Most safety shutoff valves (SSOVs) are serviceable.

A

False.

95
Q

What should be done with auxiliary power supplies after valve leak testing?

A

Remove all auxiliary power supplies and jumpers used during testing.

96
Q

What is the purpose of a safety shut-off valve (SSOV)?

A

To prevent gas leaks and ensure safety in fuel delivery systems

SSOVs are critical in maintaining system integrity and safety.

97
Q

True or False: Most SSOVs are serviceable and can be repaired if they break down.

A

False

Many SSOVs, such as Maxon and Eclipse, are non-serviceable.

98
Q

What components can be replaced in non-serviceable SSOVs?

A

Proof of closure switches

Some parts may still be replaceable even if the valve itself cannot be repaired.

99
Q

Which solenoid valves can be repaired with kits?

A

ASCO valves

Repair kits typically include diaphragm, spring, O-rings, etc.

100
Q

What is the Honeywell V4055 actuator’s serviceability status?

A

Non-serviceable and needs replacement

Core replacement may offer discounts on rebuilt actuators.

101
Q

What should be done before applying oil to cams and linkages?

A

Inspect and clean the cams

This ensures proper lubrication and functionality.

102
Q

What is one of the top causes of motor failure?

A

Bearing failure

Regular greasing of bearings is crucial to prevent this issue.

103
Q

What factors determine the greasing schedule for motor bearings?

A

Motor load, run time, and ambient temperature

These factors influence how often bearings should be greased.

104
Q

Fill in the blank: Over-greasing can cause _______.

A

Internal bearing pressure

This can lead to higher friction and potential damage.

105
Q

What is the first step in greasing motor bearings?

A

Ensure the motor is running and warm

This helps with grease application.

106
Q

What should you do if you see grease coming out of the purge valve while greasing?

A

Stop adding any more grease

This prevents overfilling issues.

107
Q

What is essential to clean before dispensing grease?

A

Grease fittings and the grease gun

This avoids adding contaminants to the grease.

108
Q

What is the purpose of a combustion air pressure switch?

A

To ensure proper flow of combustion air before ignition

This is a safety device in fuel delivery systems.

109
Q

How can you test for continuity in a combustion air pressure switch?

A

Use a multimeter to measure continuity after disconnecting the wires

A click should be heard when blowing into the tubing.

110
Q

What should be done if the air pressure switch does not activate at the correct setting?

A

Replace the switch

This indicates that the switch may be faulty.

111
Q

What method is recommended for heating bearings before installation?

A

Using a proper induction heater

Avoid using risky shortcuts like torches.

112
Q

What should be checked when installing a new bearing?

A

Ensure correct size and sufficient heating

Proper alignment is crucial to avoid damage.

113
Q

What types of tests are performed when testing an electric motor?

A

Electrical tests, vibration tests, thermal tests, dynamic tests, noise tests, insulation tests

These tests assess the motor’s performance and safety.

114
Q

What does a megger test measure?

A

Insulation resistance

It helps identify weaknesses in insulation that can lead to electrical failure.

Gas A Level 2 (22 decks)

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