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Gas A Level 2 > Block 2 - Commission Fuel Train Components & ICI Burners > Flashcards

Block 2 - Commission Fuel Train Components & ICI Burners Flashcards

1
Q

What is the responsibility of a technician when commissioning an appliance?

A

You become responsible for any appliance you commission regardless of whether you pulled the permits or not.

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2
Q

Before commissioning an appliance not installed by your company, what should you verify?

A

Check if all appropriate permits are in order by contacting the safety officer.

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3
Q

What information does a gas safety officer need for commissioning?

A
  • Customer name
  • Company site name and address
  • Manufacturer and type of appliance
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4
Q

What is the CRN# used for?

A

It will give you a complete history of the boiler, from the manufacturer to the present.

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5
Q

What types of permits are needed for commissioning?

A
  • Piping installation permit
  • Appliance installation permit
  • Appliance product approval permit
  • Boiler installation permit
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6
Q

What should be checked during a site visit prior to commissioning?

A
  • Gas piping size and pressure
  • CSA approval for the appliance
  • Fuel train compliance
  • Flu venting correctness
  • Combustion air requirements
  • Gas meter size
  • Electrical completeness
  • Feed water and boiler piping
  • Air dampers and gas linkages
  • Gas pressure adequacy
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7
Q

What should be done with all gas firing valves before starting checks?

A

Close all gas firing valves.

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8
Q

What does PTFI stand for?

A

Pilot Trial for Ignition.

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9
Q

What is the purpose of a pilot turn down test?

A

To ensure that the smallest pilot flame will hold in the flame relay and ignite the main flame safely.

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10
Q

What is the turndown ratio in relation to firing rate?

A

It indicates the flexibility of the burner to satisfy heating demands without cycling.

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11
Q

What is the initial airflow setting based on?

A

The calculated combustion air requirements.

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12
Q

What is excess air in combustion?

A

The amount of air supplied beyond the stoichiometric requirements for complete combustion.

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13
Q

True or False: A zero governor system allows for more than two adjustments.

A

False.

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14
Q

What adjustments are made for high fire settings?

A

Adjust the high fire air/gas ratio by turning the air valve and adjusting the limiting orifice gas valve.

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15
Q

What is the purpose of an impulse line in a combustion system?

A

To correct the regulator action and compensate for variable combustion chamber pressure.

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16
Q

Fill in the blank: The _____ needs to be checked and confirmed during the commissioning process.

A

combustion analysis

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17
Q

What is the significance of checking gas inlet pressures?

A

To ensure proper function of high and low gas pressure switches.

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18
Q

What should be done if clocking is not possible due to other appliances firing?

A

An orifice plate may need to be installed.

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19
Q

What is the role of the line pressure regulator?

A

To set the initial pressure settings for a burner based on manufacturer specifications.

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20
Q

What should be monitored during airflow adjustments?

A

Combustion parameters such as flame appearance, stability, and color.

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21
Q

What is the recommended excess air percentage for adjustments?

A

Around 3% to 5% excess air.

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22
Q

What is the effect of combustion chamber pressure fluctuations?

A

It can upset control of the system.

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23
Q

What is the minimum inlet pressure required for a regulator sized to take a 3 iwc pressure drop at full fre conditions?

A

31 iwc or more

This is calculated by adding the pressure drop (3 iwc) to the desired outlet pressure (28 iwc)

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24
Q

What is the desired safety factor added to the required supply pressure?

A

2 in

This is added to ensure a margin of safety in pressure supply

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25
Q

What is the required supply pressure if the regulator is sized for a 10 in wc drop?

A

40 in

This is calculated by adding the pressure drop (10 in) to the desired outlet pressure (28 in) and the safety factor (2 in)

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26
Q

What should be checked when commissioning an appliance with a fan-assisted burner?

A

Manufacturer’s installation instructions

It is crucial to follow specific guidelines to ensure safety and proper operation

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27
Q

True or False: If the draft is too low, you should remove weight from the damper chain.

A

False

Adding weight to the damper chain will choke dilution air and increase the draft

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28
Q

What should be done if the draft is too high?

A

Remove weight from the damper chain

This adjustment allows more dilution air in and decreases the draft

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29
Q

What is the purpose of the FGR inlet box?

A

Pulls fuel gas from the sack and delivers it to the combustion air fan inlet

This is essential for the proper operation of a FGR system

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30
Q

What is the function of the FGR flow control damper?

A

Regulates the quantity of fuel gas to the FGR inlet box

It is designed for high-temperature operation and is driven by a damper actuator

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31
Q

Fill in the blank: The ductwork must be installed to be ______ with high temperature gasketing at duct joints.

A

gas tight

Ensuring gas-tight ductwork prevents leaks and maintains system efficiency

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32
Q

What should be done if the temperature in the ductwork exceeds a maximum set point?

A

Shut down the burner

This prevents damage to FGR components due to backflow from the boiler

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33
Q

What is a crucial step during the FGR system start-up procedure?

A

Review the burner instruction manual

This ensures that all safety checks and standard procedures are followed

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34
Q

What happens if the burner is operated without the FGR blower in operation?

A

Overheating and possible damage to the FGR manifold assembly

This can compromise the safety and functionality of the system

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35
Q

What is the recommended setting for the stack temperature switch?

A

A few degrees below the normal low fire sack temperature

This ensures the system operates safely and effectively

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36
Q

What is the relationship between FGR rate and combustion air flow?

A

Increasing the FGR rate will lower the combustion air flow

This is indicated by lower sack O2 levels

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37
Q

What is the effect of too much FGR on combustion stability?

A

Can cause instability and combustibles (CO or smoke)

It is essential to fine-tune the FGR damper position for optimal performance

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38
Q

What should be done to ensure the burner can ramp from low fire to high fire and back?

A

Make adjustments at each load point until proper emissions and performance are achieved

Each adjustment should be monitored for stability and efficiency

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39
Q

What are burner pulsations also known as?

A

Combustion instabilities

These can affect the efficiency and safety of the burner operation

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40
Q

What are burner pulsations?

A

Burner pulsations, also known as combustion instabilities, are fluctuations in flame intensity caused by various factors.

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41
Q

What can cause fuel-air mixture imbalance?

A

An improper balance of fuel to air can lead to incomplete combustion and fluctuations in flame intensity.

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42
Q

Name two factors that affect flame stability.

A
  • Flame shape
  • Flame size
  • Flame position within the combustion chamber
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43
Q

How does combustion chamber design contribute to burner pulsations?

A

Poor combustion chamber design can create conditions conducive to pulsations due to inadequate mixing of fuel and air or improper geometry.

44
Q

What impact does fuel quality have on combustion stability?

A

Variations in fuel quality, including changes in composition or impurities, can impact combustion stability and contribute to pulsations.

45
Q

List three issues related to burner design and operation that can cause pulsations.

A
  • Improper nozzle sizing
  • Clogging
  • Malfunctioning controls
46
Q

What operating conditions can affect combustion dynamics?

A
  • Load fluctuations
  • Ambient temperature
  • Pressure variations
47
Q

How can mechanical vibrations influence combustion stability?

A

External mechanical vibrations from nearby equipment or structural resonance can influence combustion stability and cause pulsations.

48
Q

What ignition problems can lead to burner pulsations?

A

Inconsistent or delayed ignition can disrupt the combustion process and result in pulsations.

49
Q

Fill in the blank: Certain combustion instability modes, such as ________, can occur under specific conditions and cause pulsations.

A

[thermo-acoustic oscillations or vortex shedding]

50
Q

What role does system feedback play in combustion instabilities?

A

Feedback mechanisms within the combustion system, such as acoustic resonance or pressure fluctuations, can amplify combustion instabilities and lead to pulsations.

51
Q

What maintenance issues can contribute to burner pulsations over time?

A

Lack of regular maintenance, including cleaning of burner components and calibration of controls.

52
Q

What should you check to ensure a steady fuel supply to the burner?

A

Ensure that there’s a steady and adequate supply of fuel to the burner.

53
Q

Why is it important to inspect combustion air supply?

A

Inadequate air supply can lead to incomplete combustion and pulsations.

54
Q

What should be examined in the burner assembly to prevent pulsations?

A

Examine the burner assembly for any signs of damage, clogging, or misalignment.

55
Q

What role do burner controls play in burner operation?

A

Malfunctioning controls can cause erratic burner operation.

56
Q

What should be monitored to identify the source of pulsations?

A

Monitor combustion parameters such as flame stability, fuel-air ratio, and combustion efficiency.

57
Q

What can be done if the fuel nozzle is clogged or worn?

A

Clean or replace the nozzle as needed.

58
Q

How can mechanical vibrations from nearby equipment affect the burner operation?

A

They can influence combustion stability and contribute to pulsations.

59
Q

What should you do if there are changes in operating conditions?

A

Consider any variations in fuel quality or load demand that may contribute to burner pulsations.

60
Q

What is the purpose of consulting the manufacturer’s guidelines?

A

To refer to specific troubleshooting steps and recommended maintenance procedures.

61
Q

What is a recommended practice during test runs to diagnose pulsations?

A

Conduct test runs with gradual adjustments to burner settings while monitoring for changes in pulsation behavior.

62
Q

What is the purpose of the procedure developed in B149.3 Annex A?

A

To help ensure safe start-up of high input gas-fired equipment

The procedure acknowledges variation in equipment types and controls.

63
Q

What should be confirmed regarding the valve train before start-up?

A

The valve train must be code compliant for the burner input of the appliance

More information can be found in B149.3 Annex B – Valve Diagrams.

64
Q

What does ASME CSD1 recommend regarding the installation of a strainer?

A

The installation of a strainer before the horizontal components in the gas train

It is a recommendation, not a requirement.

65
Q

What is the requirement for testing the valve seats?

A

The valve shall be tested to ensure gas-tightness of the valve seats when in the closed position.

66
Q

What should be checked with the Appliance shutoff valve?

A

There should be no pressure downstream when the Appliance shutoff valve is closed.

67
Q

What should be monitored when checking tightness of closure for the SSOVs?

A

Monitor pressure upstream and downstream of the SSOVs as you cycle the individual valves.

68
Q

What type of valve is recommended for test firing?

A

A test firing valve of the quarter-turn type, certified to CGA 3.11, CGA 3.16, or ANSI Z21.15/CSA 9.1.

69
Q

What is the maximum allowable closing time for electro-hydraulic SSOVs?

A

They are required to close within 1 second.

70
Q

What is the purpose of a Valve Proving System (VPS)?

A

To cycle the valves and monitor pressures automatically at the beginning of each cycle.

71
Q

What is the difference between Passive VPS and Active VPS?

A

Passive VPS is a static system; Active VPS is a separate system with advanced instrumentation.

72
Q

What does B149.3 clause 4.4 state about pressure regulators?

A

The pressure regulator shall maintain an outlet pressure within 10% of the set pressure during burner operation.

73
Q

What is required when the inlet supply pressure to the pressure regulator exceeds 0.5 psig?

A

The pressure regulator shall be a lock-up (positive shut-off) pressure regulator.

74
Q

What is the function of gas pressure switches?

A

To monitor the functionality of the regulator and shut down the burner if unsafe conditions arise.

75
Q

Fill in the blank: A high gas pressure safety device shall initiate shut-off of the supply of gas when the gas pressure exceeds _______.

A

125% of the normal operating pressure at the maximum firing rate.

76
Q

What must be checked regarding the operation of the Proof of Closure switch?

A

Confirm the operation of the Proof of Closure switch if equipped.

77
Q

True or False: The valve seat ‘bubble’ test is an annual maintenance requirement for most fuel-fired equipment standards.

A

True.

78
Q

What should be confirmed when adjusting gas pressure regulators?

A

Confirm that the amount of droop or boost does not exceed what is allowed.

79
Q

What is the purpose of Overpressure Protection (OPP)?

A

To protect the system from excessive pressure situations.

80
Q

What conditions might require a low gas pressure safety device?

A

If the pressure at the point of connection drops below 50% of the lowest normal operating pressure.

81
Q

What should be monitored when installing a manometer or pressure gauge?

A

Monitor the pressure between the SSOVs for any increase that indicates a leaking first valve.

82
Q

What is the consequence of not ensuring tight shut-off of fuel valves?

A

Foreign material may prevent tight closure, leading to leakage and potential hazards.

83
Q

What is the function of the low gas pressure safety device?

A

Bypassed into the combustion safety control until the burner has started.

This is a precaution to ensure safety during the ignition process.

84
Q

When is the lowest normal operating pressure observed in a gas burner?

A

While the burner is at high fire and the regulator is experiencing its maximum allowable droop.

85
Q

What do modern unified valves combine?

A
  • Pressure regulation
  • Valve closing
  • Variable flow rate
  • Pressure switches

Consult manufacturers’ documentation for specific adjustments.

86
Q

What is the purpose of the Proof of Closure option?

A

To ensure that the valve is fully closed when required.

87
Q

How should the position of the flow control valve be adjusted?

A

For the different firing rates while setting combustion and using a combustion analyzer.

88
Q

What does the fuel cam control in a burner?

A

The position of the input flow control valve.

89
Q

According to B149.3 Clause 8.2.2, what features must an automatic input flow control valve have?

A
  • Capable of adjustment for sufficient gas
  • Means for preventing accidental change in settings
  • Accessible for service and adjustment
90
Q

What should be done when making fuel adjustments?

A

Set and lock the high fire and low fire stops on the overtravel linkage.

91
Q

What does the FARC system stand for?

A

Fuel Air Ratio Control.

92
Q

What is a characteristic of a parallel position system in FARC?

A

Individual actuators facilitate precise adjustment to a single valve or damper position.

93
Q

What is the role of instrumentation in sophisticated systems?

A

To determine real-time flow rate to the burner for adjustment and calibration.

94
Q

How are oil burner valve trains arranged compared to gas fuel valve trains?

A

They are arranged similarly with some exceptions.

95
Q

What is an ‘oil block’ in oil burner valve trains?

A

Several oil valve train components combined into a single device, with each function still requiring separate adjustments.

96
Q

What components should be included in an oil burner system?

A
  • Strainer
  • Filter
  • Water separator

This is essential for maintaining fuel quality.

97
Q

Where can the oil pump be located in an oil burner system?

A

On the appliance or further upstream in the piping.

98
Q

What affects the pressure to the oil nozzle in an oil burner?

A

How the oil is atomized (e.g., air atomized, pressure atomized, steam atomized).

99
Q

How do pressure atomized nozzles maintain nozzle pressure?

A

By adjusting the bypass regulator.

100
Q

What are SSOVs in a fuel system?

A

Normally closed solenoid valves that are piped in series and wired in parallel as a double block.

101
Q

What is the purpose of metering valves in an oil burner?

A

To provide precise control of the fuel oil.

102
Q

What is a metering sem?

A

A component that can be lowered or raised to expose more or less of the cut V-groove.

103
Q

What challenges arise in a dual gas fuel system?

A

Some parts of the valve train will be independent to each fuel, while others will be common.

104
Q

What is the adjustment priority in linkage systems for combustion settings?

A

Adjust the air damper linkage for the primary fuel first, then the secondary fuel.

105
Q

How is each fuel curve adjusted in appliances with parallel position systems?

A

Independently for each fuel and air trimmed independently.

Gas A Level 2 (22 decks)

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