Routine Boiler Maintenance and Inspections

Question 1

Before welders are allowed to weld on a boiler they must have a:

A) Performance qualification card
B) Certificate of qualification
C) Welding test conducted
D) Certificate of qualification and a performance qualification card
E) Certain minimum number of years experience

Answer 1

D) Certificate of qualification and a performance qualification card

Question 2

If there is a possibility of freezing, the best method for layup is the:

A) CO2 method
B) Glycol method
C) Wet method
D) Dry method
E) Nitrogen cap method

Answer 2

D) Dry method

Question 3

The wet method of boiler storage requires the boiler to be:

A) Scale free
B) Filled with distilled water
C) Completely filled with water to exclude air
D) Boiled out
E) Chemically cleaned

Answer 3

C) Completely filled with water to exclude air

Question 4

Leaks in steam, water and fuel connections:

A) Can be ignored until the next shut down
B) Are not an operation issue
C) Only need to be contained
D) Are not important
E) Can cause damage due to wire drawing

Answer 4

E) Can cause damage due to wire drawing

Question 5

The purpose of an alkaline boil out of a boiler is to:

A) Remove bicarbonate scale
B) Remove silica scale
C) Neutralize ash deposits
D) Neutralize acidic materials
E) Remove grease, oil or other contaminants

Answer 5

E) Remove grease, oil or other contaminants

Question 6

A hydrostatic test consists of filling the boiler:

A) Completely full and pressurizing it with air
B) To operating level and pressurizing it with a pump
C) Operating level and pressurizing it with nitrogen
D) Completely full of water and pressurizing it with a pump
E) ½ full and pressurizing it with air

Answer 6

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

Question 7

One of the legal responsibilities of the engineer during an inspection is:

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

Answer 7

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

Question 8

A failed firetube may be detected by:

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

Answer 8

D) All of the above

Question 9

The black light method of crack detection uses fluorescent:

A) Cameras
B) Isotopes
C) Paint
D) Lights
E) Penetrant

Answer 9

E) Penetrant

Question 10

A hydrostatic test is carried out at:

A) 2 times the MAWP
B) MAWP (Maximum Allowable Working Pressure) of the boiler
C) 3 times the MAWP
D) ½ times the MAWP
E) 1 ½ times the MAWP

Answer 10

E) 1 ½ times the MAWP

Question 11

A very important job during an internal inspection in regard to safety is:

A) Looking for evidence of damage
B) 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
C) Servicing combustion equipment
D) Looking for evidence of scale
E) Ensuring that all equipment is in good operating condition

Answer 11

B) 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 12

The most common acid for boiler cleaning is:

A) Hydrochloric
B) Nitric
C) Chelate
D) Sulphuric
E) Phosphoric

Answer 12

A) Hydrochloric

Question 13

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) Removed by the owner
D) Authorized to be removed by the plant manager
E) Removed by the person directly in charge of the job

Answer 13

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

Question 14

During a hydrostatic test:

A) Safety valves must be removed and blanked off
B) All of the above
C) Air must be completely removed from the boiler
D) Water temperature should be at ambient temperature
E) All instruments and fittings not rated for 1 ½ times MAWP must be removed or isolated

Answer 14

B) All of the above

Question 15

A boiler inspection:

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

Answer 15

B) Must be done when the boiler inspector requests it

Question 16

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) Spontaneous combustion of the soot
B) Corrosion of the metal surfaces
C) Formation of toxic fumes
D) Fireside will be inaccessible for inspection
E) Crystallization of the ash

Answer 16

B) Corrosion of the metal surfaces

Question 17

Portable lamps used during the internal inspection of a boiler must be:

A) Greater than 120 V
B) 100 W
C) 12 V or less
D) 24 mV
E) 347 V

Answer 17

C) 12 V or less

Question 18

The dry method of boiler storage uses slaked lime, activated alumina, or silica gel to:

A) Control the pH of the boiler water
B) Adsorb chemical odours in the boiler
C) Adsorb oxygen from the air
D) Prevent vermin from entering the setting
E) Adsorb moisture from the air

Answer 18

E) Adsorb moisture from the air

Question 19

When removing a boiler for service, the topmost manhole covers should be removed first to:

A) Aid in the draining process
B) Get the process done while the boiler is draining
C) Prevent steam burns caused by the circulating effect
D) Allow for gasket replacement
E) Prevent air damaging waterside surfaces

Answer 19

C) Prevent steam burns caused by the circulating effect

Question 20

A steam heating boiler that is to be shutdown for a considerable length of time should be:

A) Left with the water at normal working level but opened up to atmosphere
B) Filled completely with water and the vent left open to atmosphere
C) Drained, thoroughly dried out, lime placed inside and closed up
D) Left with the water at normal working level and pressurised with air to 50 kPa
E) Drained, thoroughly dried out, lime placed inside and left open

Answer 20

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

Question 21

An inhibitor, when added to acid will:

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

Answer 21

B) Minimize the effect the acid has on the metal

Question 22

A relatively new and safer chemical used in boiler cleaning is:

A) Chelate
B) Sodium hydroxide
C) Hydrazine
D) Caustic soda
E) Trisodium phosphate

Answer 22

A) Chelate

Question 23

Causes of firetube failure are:

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

Answer 23

A) All of the above

Question 24

A boiler circulating pump gland should have some leakage:

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

Answer 24

E) To prevent the packing from drying out

Question 25

When washing the boiler out, it is essential to ensure that:

A) Handhole gaskets have been replaced
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) Low water cut offs are removed

Answer 25

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