Block 2 - Appliance Startup Procedures - Commission Flame Safeguard Systems Flashcards
What are the regulatory requirements for gas appliances?
Obtain necessary permits, secure product approval, complete field inspections.
Failure to adhere could have serious consequences for your career as an Industrial Gasfitter.
How does Technical Safety BC evaluate applications for product approvals?
On a case-by-case basis, requiring certification by a recognized body if a Canadian-recognized standard or other recognized document exists.
What is the first step for non-certified appliances lacking Canadian certification?
Apply to register the uncertified gas appliance (Gas Design Registration).
What must be obtained after receiving a journal number for a design?
Product Approval permit.
What is required after completing each phase of the gas system authorized by the permit?
Request an inspection.
What must be done during commissioning of a gas appliance?
A Safety Officer will field certify the unit and affix a decal.
What does the complete Product Approval include?
Commissioning permission.
What does section 31 of the Gas Safety Regulations state?
A person must not install an appliance unless it displays a certification mark or an approval mark.
What are potential penalties for performing regulated work without a permit?
Fines up to $100,000 and/or imprisonment for up to 18 months for individuals; fines up to $200,000 for corporations.
What appliances require mandatory commissioning approval under section 26 (2) of the Gas Safety Regulations?
Direct-fired non-recirculating make-up heater, conversion burners, direct-fired equipment, forced draft appliances over 409,600 Btuh.
How much notice must the permit holder give before requesting an assessment?
At least 48 hours prior to expected commissioning time.
Who witnesses the testing and commissioning of the appliance?
The safety officer.
What should be done if the commissioning approval assessment is waived?
Submit a Start Up report to the safety officer.
What should be initiated early in the commissioning process?
Communication between the gas fitter of record and the Gas Safety Officer.
What must gas fitters submit to Technical Safety BC after a start-up?
A detailed appliance start-up report.
What should the start-up gas fitter information match?
The gas fitter of record on the permit application.
What is required for the setup and training of the operator?
Manuals and wiring diagrams.
What should be checked during a pre-start-up inspection?
Function of gaskets, removal of packing, compliance of valve train, and system connections.
What are some items to check during commissioning?
- Function of gaskets
- Valve train compliance
- System connections
- Electrical terminations
- Belt and pulley alignment.
What must be confirmed regarding wiring before start-up?
Wiring is complete and as per drawings.
What must be checked regarding motor rotation?
Correct rotation of 3-phase motors.
How can the rotation of a 3-phase motor be changed?
Interchanging any two of the three lines feeding the motor.
What must be done to ensure safety during the commissioning process?
Perform a Job Hazard Assessment.
What is the importance of checking every single wiring termination?
To prevent system failures due to loose connections.
True or False: Personal locks may be accepted on all industrial sites.
False.
Fill in the blank: A complete Product Approval includes _______.
[commissioning permission].
What is the primary hazard associated with flame safeguards?
Fire or Explosion Hazard. Can cause property damage, severe injury or death.
What must be done before starting tests on flame safeguards?
Close all manual fuel shutoff valve(s).
What should be confirmed regarding the flame safeguard model?
Confirm that the model is correct and meets all code requirements for the application.
What is necessary regarding grounding when installing a flame safeguard?
Confirm that there is a connected dedicated ground wire installed on the subbase.
What should be checked for tightness during installation?
Check the tightness of every wiring terminal.
What is the purpose of performing a static checkout?
Verify that the subbase is wired correctly, and the external controllers, limits, interlocks, actuators, valves, transformers, motors, and other devices are operating properly.
What is required to complete some of the tests during the static checkout?
Gas pressure to the low gas pressure switch, or it needs to be jumped out.
What tools are needed for performing the static checkout?
A multi-meter and a pair of 14 AWG jumpers with alligator clips at each end.
Fill in the blank: To perform the Static Checkout, you will need a _______.
[multi-meter]
What should be done before opening the main disconnect when adding or removing jumpers?
Open the master switch.
What is the first test conducted during the static checkout?
Check supply power.
What voltage should be checked between terminals 5 (L1) and L2?
Supply power voltage.
What is the second test during the static checkout?
Check Limit Circuit.
What should be checked if the voltage reading is abnormal?
Check the limit circuit components.
What is the purpose of the lockout interlocks test?
Ensure the system locks out correctly when conditions are not met.
What should be observed during the ignition transformer test?
You should hear the buzz of the ignition spark.
What should be heard when checking the pilot valve?
You should hear the click of the opening of the pilot solenoid valve.
What is tested in tests #6 and #7 during the static checkout?
Check Safety Shutoff Valves (SSOV’s).
What should be observed when the main gas valves are opened?
Observe the opening of the main gas valves.
What should be done after confirming the mounting base is wired correctly?
Reinstall the flame safeguard on the mounting base and proceed to testing.
What must be confirmed regarding the sequence of the flame safeguard?
You must be familiar with the specific sequencing of the model.
What is the purpose of the purge time confirmation?
Ensure the purge time is correct for the appliance/application.
What happens during the Pilot Trial for Ignition (PTFI) period?
Listen for the click of the solenoid opening and buzz of the transformer/spark.
What should the flame signal be during the Ultraviolet Ignition Spark Response Test?
Flame signal should not be greater than 0.25 Vdc.
What indicates a successful pilot flame establishment?
A steady, healthy flame signal.
What is the maximum flame signal voltage acceptable during testing?
5 VDC.
What is the minimum flame signal voltage acceptable during testing?
1.25 VDC.
What must be done to initiate a burner cycle?
Close the burner switch.
What is the expected outcome of the main burner ignition test?
Observe main burner ignition.
Fill in the blank: The flame safeguard will lock out at the end of the _______.
[Pilot Flame Establishing Period (PFEP)]
True or False: The pilot flame will terminate at the end of the Main Flame Establishing Period (MFEP).
True.
What should be observed when opening the main burner tes fring valve slowly?
Main burner ignition
If smooth and rapid, terminate burner cycle and start a third cycle.
What is the procedure for testing with an interrupted pilot?
Terminate the pilot at the end of the MFEP and lock out the control
Push the reset to start a third cycle.
What should be done during the third cycle after the pilot valve is opened?
Open the tes fring valve and observe main burner ignition.
What should be checked after closing the tes fring valve?
Flame failure response time
The flame safeguard should lock out in less than 1 sec.
In an intermittent pilot system, what additional action is required?
Close the pilot valve also.
What is the purpose of the Pilot Turndown Test?
To confirm that the smallest recognizable pilot will still light the main burner smoothly.
What should be consulted for the initial burner light-off?
Burner manufacturer instructions or flame safeguard control instructions.
What indicates a faulty UV sensor tube during the test?
A reddish glow appears when there is no flame present.
What is the significance of the Dynamic Self Check?
To confirm that the amplifier is correct.
How should the average stable reading be taken during the self-check?
Disregard the peaks caused by shutter operation.
What happens if there is a continuous signal or no signal during the self-check?
The system will lock out.
What should be done before putting the burner into service?
Check out the installation using the checkout procedures.
What is essential to do after completing the checkout procedures?
Run the burner through at least one complete cycle.
True or False: The system can be put into operation before all checkout tests are completed.
False
Fill in the blank: The self-check shutter is ______ seconds closed and ______ seconds open.
0.4 / 3.6
What is the main focus of the lesson regarding gas pressure regulators?
Regulator repair and maintenance, specifically for the Fisher LS200 Regulator.
What should be done before attempting any maintenance or disassembly of a regulator?
Isolate the regulator from system pressure and relieve all internal pressure.
How often does Fisher recommend parts replacement for regulators?
At a maximum every 10 years.
What should be avoided to prevent personal injury during diaphragm casing maintenance?
Loosening diaphragm casing cap screws when the control spring has spring force applied.
What components should be inspected and potentially replaced during disk or pad maintenance?
Disk or pad, O-ring, and locknut.
True or False: The balance diaphragm and orifice can be replaced during maintenance.
True.
What is recommended if a regulator is installed upside down or horizontally?
Readjustment is required.
What should be done with relief valve O-rings during maintenance?
Replace with new ones and lightly lubricate before assembly.
What must be done if installing a control spring of a different set pressure range?
Remove the set pressure range on the spring case and indicate the new range.
What is the standard slope for a sensing line to ensure proper drainage?
A ¼” per foot towards the gas piping.
What is the primary function of a lubricated plug valve?
To control flow by rotating the plug to align a central hole with the downstream direction.
What should be done before injecting sealant into a lubricated plug valve?
Ensure that the equipment is shut down and automatic shutoff valves are closed.
Fill in the blank: A lubricated plug valve consists of a plug and a _______.
body.
What should be used to coat the adjusting screw during relief valve maintenance?
Anti-seize compound.
What method is preferred for injecting sealant into a lubricated plug valve?
Sealant Gun Service (Using Injection Gun).
What should be done if the pressure doesn’t rise during sealant injection?
Check if the gun is out of sealant, valve seat is leaking, or packing gland is loose.
What is the suggested procedure for testing safety shutoff valves?
Perform a valve leak test annually or during PM maintenance.
What equipment can be used to measure valve leakage?
A 6 mm (0.25 inch) O.D. x 1 mm (0.032 inch) wall tube submerged in water.
What should be done if valve testing indicates leakage exceeding 15 bubbles per minute?
Perform pre-operational exercising (valve cycling) and retest the valve.
What is the first step in the testing procedure for Maxon’s double blocking shut-off valves?
Shut down combustion system per manufacturer’s recommended procedure.
What should be checked visually before testing shut-off valves?
Verify that shut-off valves #1 and #2 are closed.
True or False: Most safety shutoff valves (SSOVs) are serviceable.
False.
What should be done with auxiliary power supplies after valve leak testing?
Remove all auxiliary power supplies and jumpers used during testing.
What is the purpose of a safety shut-off valve (SSOV)?
To prevent gas leaks and ensure safety in fuel delivery systems
SSOVs are critical in maintaining system integrity and safety.
True or False: Most SSOVs are serviceable and can be repaired if they break down.
False
Many SSOVs, such as Maxon and Eclipse, are non-serviceable.
What components can be replaced in non-serviceable SSOVs?
Proof of closure switches
Some parts may still be replaceable even if the valve itself cannot be repaired.
Which solenoid valves can be repaired with kits?
ASCO valves
Repair kits typically include diaphragm, spring, O-rings, etc.
What is the Honeywell V4055 actuator’s serviceability status?
Non-serviceable and needs replacement
Core replacement may offer discounts on rebuilt actuators.
What should be done before applying oil to cams and linkages?
Inspect and clean the cams
This ensures proper lubrication and functionality.
What is one of the top causes of motor failure?
Bearing failure
Regular greasing of bearings is crucial to prevent this issue.
What factors determine the greasing schedule for motor bearings?
Motor load, run time, and ambient temperature
These factors influence how often bearings should be greased.
Fill in the blank: Over-greasing can cause _______.
Internal bearing pressure
This can lead to higher friction and potential damage.
What is the first step in greasing motor bearings?
Ensure the motor is running and warm
This helps with grease application.
What should you do if you see grease coming out of the purge valve while greasing?
Stop adding any more grease
This prevents overfilling issues.
What is essential to clean before dispensing grease?
Grease fittings and the grease gun
This avoids adding contaminants to the grease.
What is the purpose of a combustion air pressure switch?
To ensure proper flow of combustion air before ignition
This is a safety device in fuel delivery systems.
How can you test for continuity in a combustion air pressure switch?
Use a multimeter to measure continuity after disconnecting the wires
A click should be heard when blowing into the tubing.
What should be done if the air pressure switch does not activate at the correct setting?
Replace the switch
This indicates that the switch may be faulty.
What method is recommended for heating bearings before installation?
Using a proper induction heater
Avoid using risky shortcuts like torches.
What should be checked when installing a new bearing?
Ensure correct size and sufficient heating
Proper alignment is crucial to avoid damage.
What types of tests are performed when testing an electric motor?
Electrical tests, vibration tests, thermal tests, dynamic tests, noise tests, insulation tests
These tests assess the motor’s performance and safety.
What does a megger test measure?
Insulation resistance
It helps identify weaknesses in insulation that can lead to electrical failure.
