Boiler Test Flashcards
Boiler Test
1
Q
What is installed on water columns to allow cleaning and inspections?
A
1” cross tees
2
Q
Name the types of fire tube boilers.
A
- Scotch Marine
- Horizontal Return Tubular
- Vertical Wet Top or Dry Top
3
Q
What is one thing that determines to the frequency of blow downs?
A
Lab analysis
4
Q
What two main controllers are required on all hot water heating boilers?
A
Low water fuel-cutoff and excessive temperature switch
5
Q
What are two advantages of using super-heated steam?
A
- Provides more work and is more efficient.
2. Reduces erosion of turbines and piping by reducing the amount of moisture impingement.
6
Q
Conduction, convection, and radiation are three forms of _____?
A
Heat transfer
7
Q
What are the two most frequent tests performed on a boiler?
A
Blowing down the low water fuel cutoff daily and lab analysis.
8
Q
T/F A blow-down cooler and tank are required on all boilers regardless of where they are discharged to.
A
False
9
Q
What is the name of resins used in water softeners?
A
Zeolites
10
Q
Can a boiler equipped with super heater be exempt from an accumulation test?
A
Yes
11
Q
A steam boiler rated at 150 psi with a 50# safety valve setting requires how many stop valves in the bottom blow down?
A
One
12
Q
What percentage of water is converted into steam?
A
33%
13
Q
What are the two pressure switches on a boiler?
A
Two high pressure switches interlocked to shut off the main gas supply with the higher having a manual reset.
14
Q
A boiler with a BTUH of 1,622,550 and 15psi safety valve setting requires which license?
A
Boiler Operating Permit
15
Q
Two things that determine what boiler fittings are made of are __________ and ___________.
A
Pressure and Temperature.
16
Q
T/F Fire tube boilers are considered to operate from 0 - 250 psi and up to 750 bhp.
A
True
17
Q
Try cocks are effective up to what pressure?
A
250 psi
18
Q
A vertical fire tube boiler is considered to be a ______ pass boiler.
A
One
19
Q
How many lbs of water to make one lb of steam?
A
One
20
Q
When bringing a boiler up, what must be done with the super heater?
A
Drain valve kept open to ensure at least 25% of the normal steam flow is maintained through the super heater to prevent damage.
21
Q
What type of valve sits under the safety?
A
No valve is under the safety. Trick Question!!!!!!!
22
Q
What principles were the ASME boiler code founded on
A
To standardize material of construction, construction, and installation of boilers.
23
Q
Define and electric boiler.
A
A boiler that use heat by use of electrical resistance.
24
Q
Water tube boilers require a more _____ _________ operator.
A
Highly Skilled
25
Water sent to the city sewer must be below?
140 F
26
What two things are required on all boilers.
Pressure/temp combustion regulators and the required number,size, and capacity if safety or safety relief valves.
27
A boiler is operating at 425F, explain why all the water does not evaporate into steam.
Not enough latent BTUs added. Also, constant pressure and continuously adding make up water to the boiler.
28
The National Building Code states that a furnace rated over ___________ btus must be maintained in a 1 hour space.
4 million BTUs
29
With sever corrosion on piping or boiler plate, the thickness checks will be measured by ______ and _______.
Ultrasonic Testing (UT) and Eddy Current.
30
Define the heating surface on a fire tube boiler.
A fire tube boiler has fire in the tubes surrounded by water. The heating surface is the outside circumference of the tubes that is in contact with the water.
31
How much does it cost to take a stationary engineer's exam?
Per city fee schedule
32
What term is the loss of boiler plate over time due to deterioration?
Erosion
33
The __________ valve is located at the outlet of the super heater.
Safety or drain valve.
34
Low water cuttoffs must be installed with a ____ size valve that when the column is blown down, the water will lower enough to activate the low water cutoff.
3/4"
35
What is meant by a purging unit when talking about a boiler.
The volume of air needed to turn over the air on the boiler one complete cycle to scavenge the combustion chamber, boiler passes, and breaching of all combustible gases.
36
What is required for new installations of boilers at 400 psi
2 gauge glasses or 1 gauge glass and an electrical level indicator.
37
Per Chp 10 of the UMC, fuel to boilers is based on one of two things. What are they?
1. Max burner input as shown on the burner nameplate.
| 2. The nominal boiler rating as determined by the Administrative Authority having jurisdiction.
38
Analyzed boiler stack vents are made up of 2 major components. What are they?
They are analyzed for O2, CO, and CO2. The two major components are O2 and CO2.
39
T/F all open condensate return tanks with air space require a back flow preventer
False
40
List 4 things on a safety valve data plate
1. ASME Symbol Stamp
2. Manufacturing Part Number
3. Popping Pressure Setting
4. Capacity
41
Define super heated steam
Steam with a higher temperature than it was generated from.
42
_______ steam is made by maintaining a constant pressure and adding heat to the steam.
Super heated.
43
Boiler license expire on what date?
December 31st
44
Can safety relief valve outlet piping reduce from 1 1/4" to 1".
No
45
Application is good for how many days after the fee is paid?
30 days
46
Is odor added to natural gas?
Yes , Mercapatan
47
What are boiler flue gases?
Combustion gases that leave the boiler.
48
What must be taken into consideration when replacing a bottom blow-down valve?
Obtain permit from the City if Houston Administrative Authority for repairs, work and materials must compy with the City of Houston UMC, ASME Code, and NBIC.
49
Define a power hot water boiler.
> 160 psi, > 250 F
50
What is fusion temperature
The amount of heat required to change phases
51
Describe an intermittent pilot?
Comes on to light the main burner, stays on during normal ops, and shuts off with the main burner.
52
Describe an interrupted pilot?
A Pilot that comes on to light the main burner and then shuts off.
53
A boiler that operates above 15 psi steam, the condensate must be _____________
Pumped back
54
Current accepted UMC?
2012 UMC amended 2016 "Houston Amendments"
55
Where would you find and pressure of steam if you were given one or the other?
Saturated Steam Tables.
56
A bypass damper on an air heater does what?
Maintains the temperature of preheated air fed to a boiler (LP book)
57
Explain the first law of thermodynamics.
Energy cannot be created or destroyed but can be changed from one form to another (LP book)
58
How many safety valves are required on a boiler with 501 sq ft. of heating surface?
2 or more
59
What is done to a boiler every 8 hours?
Blow down gauge glass, water column and low-water fuel cut-off (LP book)
60
Oxygen is required component of ________________?
Combustion (LP book)
61
The purge just below the NOWL is (Normal Operating Water Level)
Continuous blow-down
For chemical analysis
Surface blow-down
Answer is a Continuous blow-down (LP book)
62
Explain the City of Houston Code pertaining to pilots.
No pilot shall depend on the closing of an electrical circuit to shut off the main gas supply valve (1006.7)
63
When installing an electric boiler the regulations of which of these must be followed
A.The National Electrical Code
B.The City of Houston Uniform Mechanical Code
C.The state of Texas boiler law
D. A and B
E All the above
E All the above
64
Why must a super-heater drain be kept open until the boiler is on line?
Maintain a minimum of 25% of the normal flow through the tubes to prevent damage due to overheating (LP book)
65
A steam boiler rated at 50# requires how many blow down valves?
One
66
When installing new pipe or fittings on a boiler what two things must be done?
Obtain Permit from the City of Houston Administrative Authority for repairs. Work and materials must comply with City of Houston Uniform Mechanical Code, ASME code and National Board Inspection Code for new installations (1025.5)
67
The comparison or ratio of heat supplied in fuel to heat absorber by water is defined as _______________
Thermal efficiency (LP book)
68
New boilers shall have___________ within 3 feet of the boiler gas train?
An approved manual shut off valve with handle. (2006 UMC 1008.0)
69
T/F The super-heater is used to increase steam pressure in a boiler
False (LP book)
70
The number .4335 related to one vertical foot of water is known as____________
Hydro-static pressure (LP book)
71
At what frequency should a water column and low water fuel cutoff be blown down?
At least every 8 hours (LP book)
72
T/F Saturated steam is steam which has a temperature lower than the pressure it was generated from.
False (LP book)
73
The data label on a safety relief valve has been removed. What procedure must be taken?
Remove and replace the safety relief valve
74
Coal, oil and natural gas are classified as three types of ___________________
Fuels for boilers
75
What is the lowest part of a water tube boiler?
Mud drum on a bent-tube water tube boiler. The furnace on Strait tube multiple pass
76
T/F The water tube boiler was developed to provide steam at higher pressures.
True
77
An over-speed trip is a device used to protect a _____________from damage.
Turbine
78
In some boilers the amount of moisture is reduced, and the quality of the steam is improved by using an arrangement called a __________ ____________
Steam separator
79
____________________ are used to increase the life of furnace refractory in water tube boilers
Water-walls
80
T/F The water column is used to retrieve steam which may be used external to the boiler.
False
81
What type of valve is considered to be a secondary means of determining the water level in a steam boiler?
Try cock valves
82
The operation of a dry pipe separator is based on ________________
Changing the direction of the steam flow to remove moisture
83
What is the disadvantage of carryover?
It can cause water-hammer which can cause a pipe or header to rupture
84
The location in a boiler where fuel and air mix and combustion occurs is known as the _____________?
Combustion chamber
85
What is necessary for the combustion of fuel?
Oxygen, fuel and heat
86
T/F A boiler must be blown down at least once a week?
False
87
Tensile stress usually acts upon which structural components inside the
boiler?
Stay-bolts and boiler plate
88
T/F The ASME is required to approve all new safety valves
True
89
What is the purpose of the check valve in the feed –water line going to a
Boiler?
To keep the boiler water in the boiler and prevent it from backing up into the feed-water piping.
90
Immediately below the working water level is the point at which the
____________ is taken.
(multiple choice) Continuous blow-down
91
What device is installed on the water column to warn the operator of a low or
high water condition?
Whistle or alarm
92
Most manufacturers recommend that water columns be____ ______ at least once every eight hours.
Blown down
93
Name one disadvantage when a steam boiler experiences water hammer.
It can cause pipe and/or tube rupture
94
____________valves are used as a secondary means to determine the water level in a steam boiler.
Try-cock
95
All scotch marine type boilers are considered to be what type of boiler?
Horizontal fire tubes with internal furnaces and multiple passes.
96
Explain the advantage of having a dry pipe in the upper part of the steam and water drum.
Improves the quality of the steam by reducing its moisture content therefore reducing the risk of possible water hammer and pipe rupture and protecting pipe and equipment from impingement damage. (HP Book pg. 34)
97
Describe two different methods which may be used when a boiler is to be laid up for a period exceeding one month.
Dry lay-up the boiler is air-dried, free of water with trays of silica gel or quick-lime on the water side of the boiler, wet lay-up the boiler is filled with warm water, free of air and shocked with sodium sulfite
98
What is required on the gas line within three feet of every gas fired boiler?
An approved manual shut off valve with a handle
99
Superheated steam is steam which has an increase in ___________ but no in increase in __________________
Temperature Pressure
100
A continuous flow of steam boilers are required to have how many stop
valves?
2
101
Outside screw and yoke rising spindle type valves are required when steam stop valves are ______________
2” inches in size or larger
102
Explain what a safety factor of 6 means in relation to a boiler
The boiler pressure would have to exceed 6 times the maximum allowable working pressure to burst or rupture the vessel.
103
When a boiler is completely removed or is taken out of service, what procedure should be followed?
Contact the City of Houston and State of Texas boiler inspectors
104
Explain why a normally open pilot gas valve is not permitted on boilers.
The pilot valve must fail closed and shall not depend on the closing of an electrical circuit to shut off the main gas supply.
105
```
According to the City of Houston UMC on a boiler with mechanical draft
What 2 (two) things must be done with combustion fan in regard to a boiler
```
It shall be equipped with an air switch to prove air flow and shall be interlocked to the burner to prevent gas from being fed to the burner in the absence of air flow, it must be able to supply at least 15 cubic feet of air for
Every cubic foot of gas burned.
106
T/F Compared to modern boilers, fire-tube boilers are inefficient.
True
107
Give two advantages of automatic non-return valves.
Automatically brings the boiler on line and automatically takes the boiler off line, protects the system in the event of a large steam leak
108
Explain the term to express conditions of water with pH of 7.0
Neutral, according to the PH standard which has a scale of 0-14 with 0 being acidic, 14 alkaline and 7 neutral (draw scale). Boiler water at PH of 7 would be considered out of range since 8-10PH is desired.
109
What device installed in steam piping allows the header to take or absorb pressure swings
Expansions bend or pipe rollers
110
All boilers per UMC are required to have 2 High pressure controls, describe them.
Needs two high-steam pressure limit controls interlocked to shut off the fuel supply to the main burner with the higher setting of the two having a manual reset.
111
Name two advantages of a fire-tube boiler.
Less initial cost than a water-tube boiler of the same size and requires less head room and floor space as compared to a water tube boiler of the same size.
112
The Pressure gauge device was invented by who and when.
Eugene Bourdon 1849
113
A holder of a stationary engineer license can replace a safety valve.
True
114
As a holder of a 2nd grade stationary engineer’s license, you can perform work on 200 ton HVAC Chiller
True
115
What device measures the quality of steam
Throttling calorimeter
116
Can a boiler tank with a temperature ranging between 120-150oF be piped to city sewer?
No, it must be below 140oF (1028.4)
117
In a vertical wet top the steam cannot be super-heated because the top of the tubes are ________________
Covered with water
118
What is the most common water tube boiler?
Straight tube, multiple pass
119
What size are cross tees”
1”
120
What does (V) represent?
Safety valve
121
Define blowback.
The difference in pressure from when a safety valve pops open and then closes with a definite drop in pressure.
122
Why was ASME established?
To establish standards for design, materials of construction, and installation.
123
Define Compressive stress?
Compressive stress occurs when two forces of equal intensity act from
opposite directions, pushing toward the center of an object.
124
Define tensile stress?
Tensile stress occurs when two forces of equal intensity act on an object, pulling in opposite directions. (draw a picture)
125
Define shear stress?
Shear stress occurs when two forces of equal intensity act parallel to each other . . but in opposite directions.
126
A boiler room can contain?
Steam or hot water heating boiler(s) and its fittings and appliances only.
127
Name 5 (five) ways to lose your stationary engineer license.
```
Misconduct
Incompetence
Negligence of Duties
Dishonesty
Failure to display boiler license along with renewal receipt
```
128
What stamps must you hold to repair or reseal a relief valve?
V, HV, UV (1008.2)
129
When bringing a boiler online in a battery of boilers, the steam stop valve should be opened when the pressure in the boiler is ______________ Then pressure in the header.
Less than
130
Define BTU
The amount of heat required to raise the temperature of one pound of water one degree Fahrenheit between 32oF and 212oF
131
All new boilers as per what year require low-water fuel cutoffs and pressure combustion regulators
1988 (1012.1)
132
What are the units of measure for a diaphragm draft gauge?
Inches or fractions of inches of a vertical water column
133
Define a Miniature Boiler
A power boiler having an internal shell diameter of 16 inches or less, a gross volume of 5 cubic feet or less, a heating surface of 20 square feet or less, and not exceeding 100psi. (Miniature boiler def)
134
Name two (2) reasons to have more air than needed for combustion to a boiler
To ensure complete combustion to prevent soot and smoke from unburned fuel being vented to atmosphere and harming the boiler by insulating the heating surface with soot build up, prevent a fuel rich combustion chamber and possible explosion.
135
What device is used to calibrate a pressure gauge?
Dead-weight tested
136
One cubic foot of gas needs how many cubic feet of air feed to a boiler?
Not less than 15 cubic feet
137
Describe what the heat of flue gases can be used for?
Boiler flue gases may be used in economizers to pre-heat the air or feed-water sent to the boiler
138
Define a Boiler Room
A room that contains a steam or hot water heating boiler and its fittings and appliances only (Boiler room def)
139
What is the purpose of a blow down valve?
It allows water to be removed from the bottom of the boiler for the purposes of removing unwanted sludge and sediment controlling chemical concentrations, reducing a high water level and dumping the boiler
140
What is the main purpose of bottom blow down?
To remove sludge and sediment
141
The inspector is coming to visit. What is he looking for?
Proper license enforcement
142
Electric boiler with 66kw needs how much air supplied to the boiler for combustion?
TRICK QUESTION NONE!!!!
143
Define the benefits of a continuous blow down being added to a boiler that previously had only a bottom blow-down.
Continuous blow-down more consistently controls chemical concentrations
144
What purpose does a back-flow preventer provide in regards to the city water line?
Prevents boiler water from backing up into the city water supply
145
What determines the head pressure on a static pumping system when it is down?
.4335psi per vertical foot of water in the system above the pumping station
146
The super heat ___________ rises as the steam pressure increases.
Temperature
147
Can a 3rd grade operate a 2nd grade boiler after testing and failing and waiting for his 90days to pass in order to retest?
No
148
Name one benefit of superheated steam?
It produces more work and is more efficient that saturated steam at the same pressure or it reduces erosion of turbines and associated piping by reducing the amount of moisture impingement as compared to saturated steam
149
```
What type of fuels cause a release of heat?
Coal
Natural gas
Oil
All of the above
```
All of the above
150
What is the minimum and maximum thickness for boiler plating?
¼ “Inch
151
Safety valves are rated based on?
BTUH output
152
What must you do to put a used boiler in service”
Obtain a permit from the city of Houston and the boiler shall be inspected and hydro-tested at 1 ½ times MAWP per the Administrative Authority (1005.2 & 1023.3)
153
On a new power boiler there must be the _______ label and the ____ _____ stamp.
State of Texas label & ASME Symbol stamp
154
What is the minimum size of a blow down valve on a water column?
¾ inch (1011.3)
155
Can a block valve be added under a safety relief valve?
No
156
T/F Safety valve outlet piping can be connected to other piping?
False (1008.3)
157
What is the benefit of pre-heating boiler feed-water?
Money will be saved on fuel at a rate of 1% fuel saving for every 10 degrees F rise in boiler feed-water
158
What is required immediately downstream of the manual shutoff valve in the gas line?
A union or other approved means of disconnect (1009)
159
Define a Package Boiler
May be any class of boiler defined in the City of Houston UMC and shall be a boiler equipped and shipped complete with fuel-burning equipment, automatic controls, and accessories, and mechanical draft equipment if used (def)
160
What is the minimum and maximum size for boiler blow-down piping?
1-2 ½ “ (HP book pg 41)
161
```
What chapter of the City of Houston UMC deals with boiler inspections?
2
10
20
None of the above
```
10
162
It shall be unlawful to install, repair or alter any boiler without first obtaining a __________from the building official.
Permit (1005)
163
How many BTUs are needed to evaporate 50lbs of water?
970.4btus per pound so 50 x 970.4 =48,520btu
164
How many pounds of water are required to generate 15 BHP?
34.5 x 15 = 517.5lbs
165
An electric boiler rated for 48kw needs what size of safety relief valve?
48 X 3.5 = 168lbs per hour (1027.2)
166
The maximum steam pressure reached on a boiler during an accumulation test was 745 psi. If the safety valves were properly fixed, what was the safe working pressure of the boiler?
745/1.06 = 702.83psi
167
On a steam boiler producing 21,925lbs of steam / hr how many gallons of water must be fed to the boiler?
21,925 / 8.35 = 2625 gallons per hour
168
1 gal of water = ____lbs of water
8.35
169
What is a pyrometer used for?
A pyrometer is the Thermocouple used to measure high furnace temperatures.
170
On a hot water boiler what is the purpose of the indoor overflow?
Systems equipped with an open expansion tank to satisfy thermal water expansion shall be provided with an indoor overflow from the upper portion of the expansion tank in addition to an open vent. The indoor overflow shall be carried within the building to a suitable plumbing fixture or plumbing drain to prevent overflow of the tank. (It’s a drain)
171
On a hot water boiler what is the purpose of the “Expansion tank”?
An expansion tank is a tank located above the heating unit that functions as a relief device in a hot water heating system. During normal operation the water level in the expansion tank varies as necessary to accommodate changes in water volume and relieve pressure in the system.
An expansion tank open to the atmosphere is located at the highest point in the system. A vent line on the expansion tank opens to the atmosphere to release pressure. Excess water in the system is discharged out through an over flow line.
172
On a burner management system if the natural gas header pressure is greater than the gas pressure needed for the burners what is used?
A gas-pressure regulator. There should be a gas-pressure regulator for the burners and separate gas-pressure regulator the pilot or pilots.
173
Boilers used exclusively for the production of potable hot water with a 200,000 Btu input or less and operating at 160 psi or less is regulated by what?
The Plumbing Code
174
Name the type of water tube boilers?
Bent tube (style A,D, or O)
Straight Tube
Flex Tube
Stirling and membrane
