Book 1 Chapter 12: Routine Boiler Maintenance And Inspection

Question 1

After cleaning, cast-iron boilers should be left completely filled with ________ in order to reduce corrosion.
A) Water
B) A slightly acidic solution
C) A slightly basic solution
D) A mixture of oil antifreeze

Answer 1

A) Water

Question 2

Which of the following chemicals may be placed in the shell of the boiler to absorb any traces of moisture?
A) Slack lime
B) Silica gel
C) Activated alumina
D) All of the above

Answer 2

D) All of the above

Question 3

Black light is the popular name for invisible light in the near _______ range of wave lengths.
A) Ultrasonic
B) Green light
C) Ultraviolet
D) Violet light

Answer 3

C) Ultraviolet

Question 4

Portable lamps of ________ or less, with current supplied from transformers or batteries, should be provided to eliminate the danger of electrocution to personnel inside the boiler.
A) 1.5V
B) 12V
C) 24V
D) 110V

Answer 4

B) 12V

Question 5

Hydrostatic testing of a boiler requires that the pressure be raised to __________ the Maximum Allowable Working Pressure stamped on the boiler.
A) 1.5 times
B) 2.0 times
C) 1.25 times
D) 1.0 times

Answer 5

A)1.5 times

Question 6

Chemicals used for the alkaline boil out of a boiler consist of a combination of which of the following.
A) Sodium hydroxide
B) Sodium carbonate
C) Sodium phosphate
D) All of the above

Answer 6

D) All of the above

Question 7

Before welders are allowed to weld on a boiler they must have a:
A) Certain minimum number of years experience
B) Certificate of qualification
C) Welding test conducted
D) Performance qualification card
E) Certificate of qualification and a performance qualification card

Answer 7

E) Certificate of qualification and a performance qualification card

Question 8

If there is a possibility of freezing, the best method for layup is the:
A) Wet method
B) Nitrogen cap method
C) Dry method
D) CO2 method
E) Glycol method

Answer 8

C) Dry method

Question 9

The wet method of boiler requires the boiler to be:
A) Boiled out
B) Completely filled with water to exclude air
C) Filled with distilled water
D) Scale free
E) Chemically cleaned

Answer 9

B) Completely filled with water to exclude air

Question 10

Leaks in steam, water and fuel connections:
A) Can cause damage due to wire drawing
B) Only need to be contained
C) Are not an operation issue
D) Can be ignored until the next shut down
E) Are not important

Answer 10

A) Can cause damage due to wire drawing

Question 11

The purpose of an alkaline boil out of a boiler is to;
A) Neutralize acidic materials
B) Neutralize ash deposits
C) Remove bicarbonate scale
D) Remove silica scale
E) Remove grease, oil or other contaminants

Answer 11

E) Remove grease, oil or other contaminants

Question 12

A hydrostatic test consists of filling the boiler:
A) Completely full of water and pressurizing it with a pump
B) Completely full and pressurizing it with air
C) 1/2 full and pressurizing it with a pump
D) Operating level and pressurizing it with nitrogen

Answer 12

A) Completely full of water and pressurizing it with a pump

Question 13

One of the legal responsibilities of the engineer during inspection is:
A) To notify the Worker’s Compensation Board of the inspection
B) To have at least two staff members present at all times
C) Point out any known or suspected defects to the inspector
D) To allow the inspector onto the premises, but only during normal working hours
E) To be in possession of an inspection certificate

Answer 13

D) To allow the inspector onto the premises, but only during normal working hours

Question 14

A failed firetube may be detected by:
A) Water vapour coming from the flue gas outlet
B) A hissing sound at the rear of the boiler
C) Water dripping from the front or rear boiler door seals
D) Water visible through the rear sight glass
E) All of the above

Answer 14

E) All of the above

Question 15

The black light method of crack detection uses fluorescent:
A) Penetrant
B) Isotopes
C) Lights
D) Paint
E) Cameras

Answer 15

A) Penetrant

Question 16

A hydrostatic test is carried out at:
A) 2 times the MAWP
B) 3 times the MAWP
C) 1/2 times the MAWP
D) 1 1/2 times the MAWP
E) MAWP (Maximum Allowable Working Pressure) of the boiler

Answer 16

D) 11/2 times the MAWP

Question 17

A very important job during an internal inspection in regard to safety is:
A) Servicing combustion equipment
B) Ensuring that all equipment is in good operating condition
C) Looking for evidence of scale
D) Looking for evidence of damage
E) Producing a tagging system to account for valves, circuit breakers and other devices operated or removed from service to ensure the safety of the job.

Answer 17

E) Producing a tagging system to account for valves, circuit breakers and other devices operated or removed from service to ensure the safety of the job.

Question 18

The most common acid for boiler cleaning is:
A) Chelate
B) Sulphuric
C) Hydrochloric
D) Phosphoric
E) Nitric

Answer 18

C) Hydrochloric

Question 19

A tagged valve, damper circuit breaker or other device shall not be operated until the tag is:
A) Authorized to be removed by telephone or radio
B) Removed by the chief engineer
C) Authorized to be removed by the plant manager
D) Removed by the person directly in charge of the job
E) Removed by the owner

Answer 19

D) Removed by the person directly in charge of the job

Question 20

During a hydrostatic test:
A) Safety valves must be removed and blanked off
B) Water temperature should be at ambient temperature
C) Air must be completely removed from the boiler
D) All of the above
E) All instruments and fittings not rated 1 1/2 times MAWP must be removed or isolated

Answer 20

D) All of the above

Question 21

A boiler inspection:
A) Is done with the owner’s permission only
B) Must be done when the boiler inspection requests it
C) Must be done before the boiler is ready for startup
D) Must be done after every shut down of the boiler
E) Must be done every two years

Answer 21

B) Must be done when the boiler inspection requests it

Question 22

If a cast iron heating boiler is removed from seasonal service and the soot and ashes are not removed as soon as possible the result may be the:
A) Fireside will be inaccessible for inspection
B) Spontaneous combustion of the soot
C) Corrosion of the metal surfaces
D) Formation of toxic fumes
E) Crystallization

Answer 22

C) Corrosion of the metal surfaces

Question 23

Portable lamps used during the internal inspection of a boiler must be:
A) 100 W
B) 24mV
C) 12V or less
D) 347V
E) Greater than 120V

Answer 23

C) 12V or less

Question 24

The dry method of boiler storage uses slacked lime, activated alumina, or silica gel to:
A) Absorb chemical odours in the boiler
B) Prevent vermin from entering the setting
C) Absorb oxygen from the air
D) Absorb moisture from the air
E) Control the pH of the boiler water

Answer 24

D) Absorb moisture from the air

Question 25

When removing a boiler for service, the topmost manhole covers should be removed first to:
A) Allow for gasket replacement
B) Aid in the draining process
C) Prevent steam burns caused by the circulating effect
D) Get the process done while the boiler is draining
E) Prevent air damage waterside surfaces

Answer 25

C) Prevent steam burns caused by the circulating effect

Question 26

A steam heating boiler that is to be shutdown for a considerable length of time should be:
A) Filled completely with water and the vent left open to atmosphere
B) Drained, thoroughly dried out, lime placed inside and closed up
C) Left with the water at normal working level and pressurized with air to 50 kPa
D) Drained, thoroughly dried out, lime placed inside and left open
E) Left with the water at normal working level but opened up to atmosphere

Answer 26

B) Drained, thoroughly dried out, lime placed inside and closed up

Question 27

An inhibitor, when added to acid will:
A) Prevent the acid from attacking the boiler metal
B) Strengthen the acid thereby shortening the cleaning procedure
C) Cause foaming in the boiler
D) Make the acid compatible with the sewer system for disposal
E) Minimize the effect the acid has on the metal

Answer 27

E) Minimize the effect the acid has on the metal

Question 28

A relatively new and safer chemical used in boiler cleaning is:
A) Trisodium phosphate
B) Caustic soda
C) Chelate
D) Sodium hydroxide
E) Hydrazine

Answer 28

C) Chelate

Question 29

Causes of firetube failure are:
A) Excessive firing rate/thermal shock
B) Heavy scale
C) Poor water circulation
D) Corrosion
E) All of the above

Answer 29

E) All of the above

Question 30

A boiler circulating pump gland should have some leakage:
A) In order to keep the motor amperage down
B) To prevent the packing from drying out
C) So the operator can tell when the pump becomes vapour bound
D) So that the shaft sleeve will take the wear
E) In order for the stuffing box to run at the desired high temperature

Answer 30

B) To prevent the packing from drying out

Question 31

When washing the boiler out, it is essential to ensure that:
A) Low water cut offs are removed
B) Safety valves are removed
C) The water column is blanked off
D) No blow back into the boiler from the blowdown system can occur
E) Handhole gaskets have been replaced

Answer 31

D) No blow back into the boiler from the blowdown system can occur

Question 32

In the circulating method, the acid solution is circulated continuously through the unit at a temperature of about ______ until the cleaning action is completed as shown by tests.
A) 77ºC (170ºF)
B) 50ºC (98ºF)
C) 120ºC (248ºF)
D) 100ºC (212ºF)
E) 65ºC (150ºF)

Answer 32

E) 65ºC (150ºF)

Question 33

Tubes adjacent to sootblowers are examined for signs of ______ due to direct impingement of steam from the blowers.
A) Oxygen pitting
B) Caustic embrittlement
C) Corrosion
D) Erosion
E) Overheating

Answer 33

D) Erosion

Question 34

After cleaning, cast-iron boilers should be left completely filled with _______ in order to reduce corrosion.
A) A mixture of oil and antifreeze
B) Light oil
C) A slightly basic solution
D) Water
E) A slightly acidic solution

Answer 34

D) Water

Question 35

In the case of a firetube boiler, the scale will be formed on the outside surfaces of the tubes and may be removed by passing a _______ through the tubes.
A) Disc grinder
B) Wire brush
C) Vibrating hammer or “rattler”
D) Scale cutter
E) Tube cleaner

Answer 35

C) Vibrating hammer or “rattler”

Question 36

Although cast iron is a ______ material that cracks relatively easily, it has proven to be a satisfactory material for low pressure boilers.
A) Strong
B) Ductile
C) Malleable
D) Fragile
E) Brittle

Answer 36

E) Brittle

Question 37

Portable lamps of _______ or less, with current supplied from transformers or batteries, should be provided to eliminate the danger of electrocution to personnel inside the boiler.
A) 32V
B) 12V
C) 110V
D) 24V
E) 1.5V

Answer 37

B) 12 V

Question 38

It is unlawful to have any welder other than the holder of a Pressure Welder Certificate and a valid ________ do any welding on any pressure part of the boiler.
A) Performance Qualification Card
B) First aid certificate
C) Quality assurance card
D) Union card
E) “B” Pressure ticket

Answer 38

A) Performance Qualification Card

Question 39

Leakage of a few drops a minute leakage from the packing gland of circulating pump is desirable to prevent drying out of packing and:
A) Scoring of the shaft
B) Corrosion of the shaft
C) Over cooling of the shaft
D) Creating to large a mess
E) Prevent ingress of air.

Answer 39

A) Scoring of the shaft

Question 40

The dye penetrant, entrapped in a crack, is brought to the surface by the action of the:
A) Ultraviolet light
B) Developer
C) Ultrasound
D) Black light
E) Dye penetrant

Answer 40

B) Developer

Question 41

In the wet boiler lay up method after the boiler water has cooled it is filled:
A) To half a gauge glass
B) Completely
C) To half fill the boiler
D) To the top of the gauge glass
E) To the bottom of the gauge glass

Answer 41

B) Completely