Unit4 Boiler Plant Operation and management

Question 1

A boiler pressure explosion is NOT caused by:
Select one:
a. Scale and sludge build-up
b. Overheating
c. Insufficient combustion air 
d. Thermal shock

Answer 1

c. Insufficient combustion air

Question 2

Which of the following is NOT an important reason to take plant readings?

Select one:

a. To diagnose problems with equipment or processes.
b. To keep operators from becoming complacent.
c. To identify operating trends.
d. To compare current field conditions with the expected performance of the equipment.

Answer 2

b. To keep operators from becoming complacent.

Question 3

A slow drain test is performed to

Select one:

a. check the operation of the blowoff tank and quenching water system
b. check the blowoff valves and blowoff line for obstruction
c. check the operation of a feedwater control valve
d. check the operation of a low water cut-off

Answer 3

d. check the operation of a low water cut-off

Question 4

A boiler pressure explosion:
Select one:
a. Could be the result of water in the fuel oil
b. Could be the result of inadequate ignition
c. May be caused by a low water condition
d. Could result from a defective flame scanner

Answer 4

c. May be caused by a low water condition

Question 5

“SOP” stands for

Select one:

a. Simplified Operating Procedure
b. Standard Operating Procedure
c. Simplified Operating Practices
d. Special Operating Procedure

Answer 5

b. Standard Operating Procedure

Question 6

In the event of a power failure, which of the following will likely require a manual restart when power is restored?

Select one:

a. small condensate return pumps
b. large air compressors
c. unit heater fans
d. air dryers

Answer 6

b. large air compressors

Question 7

How often should a LWCO float chamber blowdown test be performed on a power boiler?

Select one:

a. weekly.
b. daily.
c. annually.
d. monthly.

Answer 7

b. daily.

Question 8

Boilers should be warmed up
Select one:
a. with maximum combustion air, to prevent smoking
b. rapidly, so the metal heats up faster
c. slowly, to minimize differential expansion and thermal shock
d. using only the pilot burner.

Answer 8

c. slowly, to minimize differential expansion and thermal shock

Question 9

Because natural gas is colourless and odourless, ___________ is added to the gas so that it is easier to detect a leak.

Select one:

a. mercaptan
b. propane
c. an irritant
d. fluorescent dye

Answer 9

a. mercaptan

Question 10

Rising stack temperatures, at a given firing rate, indicate
Select one:
a. Correct burner operation
b. A defective stack thermometer
c. Boiler corrosion
d. heat transfer surfaces are becoming dirty.

Answer 10

d. heat transfer surfaces are becoming dirty.

Question 11

How often should the desiccant be checked during a dry layup?

Select one:

a. Annually.
b. Bi-weekly to monthly.
c. Daily.
d. Semi-annually.

Answer 11

b. Bi-weekly to monthly.

Question 12

Who should verify a steam boiler lockout?

Select one:

a. A representative of the plant Workplace Safety and Health committee.
b. A second qualified operator.
c. Each and every contractor or employee working on the boiler.
d. Nobody.

Answer 12

b. A second qualified operator.

Question 13

A boiler furnace pre-purge:
Select one:
a. happens after the ignition transformer is energized.
b. can occur even if the boiler has a low water condition.
c. happens only when the draft fans are at low speed.
d. must last a specific amount of time.

Answer 13

d. must last a specific amount of time.

Question 14

A typical natural gas flame should be

Select one:

a. bright yellow, with orange tips.
b. bright yellow, with black tips.
c. blue, with orange at the tip of the flame
d. asymmetrical, and as close as possible to the heat transfer surfaces.

Answer 14

c. blue, with orange at the tip of the flame

Question 15

Larger capacity, high pressure fuel trains are

Select one:

a. simpler
b. safer
c. more efficient
d. more complex

Answer 15

d. more complex

Question 16

While a boiler is warming up, it is good practice to:
Select one:
a. make the manhole and handhole gaskets as tight as possible
b. ensure proper operation of the low water fuel cut-off.
c. perform a try-lever test before the boiler develops pressure.
d. operate the sootblowers.

Answer 16

b. ensure proper operation of the low water fuel cut-off.

Question 17

A high water level in a boiler:
Select one:
a. Will cause the high water cut-off to shut down the boiler
b. Is usually caused by a boiler feed pump malfunction
c. Will necessitate an immediate shutdown and cool down
d. May cause water carryover into the header

Answer 17

d. May cause water carryover into the header

Question 18

One way to keep oxygen out of the boiler water system is to:
Select one:
a. Increase the continuous blowdown to remove water with high dissolved oxygen concentration.
b. Keep make-up water to a minimum.
c. Keep the drum vent closed when the boiler is not in operation.
d. Control the boiler water pH.

Answer 18

b. Keep make-up water to a minimum.

Question 19

How often should operator rounds be performed?

Select one:

a. every hour
b. once a week
c. 1 to 3 times per shift
d. every day

Answer 19

c. 1 to 3 times per shift

Question 20

On a boiler fuel system that has a “double block and bleed” arrangement:
Select one:
a. The ”bleed” valve is a normally open solenoid valve.
b. The main SSOVs energize when the bleed valve de-energizes.
c. The main SSOVs open before the pre-purge occurs
d. The main SSOVs and the vent valves open at the same time.

Answer 20

The ”bleed” valve is a normally open solenoid valve.

Question 21

Mechanical chart recorders

Select one:

a. need their charts replaced each month.
b. require regular replacement of paper and ink.
c. are used so regular readings do not need to be taken.
d. require constant winding of their clock mechanisms.

Answer 21

b. require regular replacement of paper and ink.

Question 22

If a power failure occurs, which of the following valves fail open?

Select one:

a. Main fuel safety shut-off valve.
b. Boiler feedwater valve.
c. Fuel line bleed valve.
d. Pilot fuel safety shut-off valve.

Answer 22

c. Fuel line bleed valve.

Question 23

What is usually considered the first task when coming onto a shift:

Select one:

a. Check water levels
b. complete the water tests
c. read the log book
d. perform a complete set of operator rounds

Answer 23

c. read the log book

Question 24

When cooling down a steam boiler that has been taken out of service, a vent valve on a steam drum should be opened to:
Select one:
a. Prevent a vacuum from forming in the boiler
b. Release air from the boiler
c. Allow for the increase of the water content as steam condenses
d. Let the operator know when the steaming has ended

Answer 24

a. Prevent a vacuum from forming in the boiler

Question 25

If a boiler sustains a low water condition
Select one:
a. use cool feedwater to quench any overheated heating surface.
b. shut down the burner, let the boiler cool slowly, then drain and inspect it for damage due to overheating.
c. immediately feed water into the boiler to raise the level.
d. open the safety valve or drum vent valve to release pressure.

Answer 25

shut down the burner, let the boiler cool slowly, then drain and inspect it for damage due to overheating.

Question 26

If a steam boiler is in service and no water level shows in the gauge glass, the first action would be to:

Select one:

a. operate the bottom blowoff valves.
b. shut off the fuel and air to the furnace
c. start the standby feed pump
d. determine whether the gauge glass is completely full or completely empty.

Answer 26

d. determine whether the gauge glass is completely full or completely empty.

Question 27

To confirm a hot water heating system is full,

Select one:

a. the expansion tank level must be at 1/2 a glass.
b. the pressure shown on the tridicator gauge must exceed the altitude indication.
c. the system pressure must be the same at every elevation.
d. the altitude shown on the tridicator gauge must exceed the pressure indication.

Answer 27

the pressure shown on the tridicator gauge must exceed the altitude indication.

Question 28

How often should the low water cut-off of a low pressure steam heating boiler be blown off?
Select one:
a. Daily 
b. Monthly
c. Twice per shift
d. Weekly

Answer 28

a. Daily

Question 29

To prevent water hammer and the severe damage it causes, it is imperative that

Select one:

a. boilers are warmed slowly.
b. steam traps are isolated during warm up.
c. steam lines and headers are isolated before boilers are started.
d. steam lines and headers are warmed up before admitting steam to the steam lines.

Answer 29

d. steam lines and headers are warmed up before admitting steam to the steam lines.

Question 30

When a power failure occurs, control valves

Select one:

a. fail shut.
b. go to a fail-safe position.
c. fail open.
d. fail last.

Answer 30

b. go to a fail-safe position.

Question 31

Before performing a try lever test on a power boiler, what pressure should the boiler be at?

Select one:

a. the boiler MAWP
b. at or above 750 kPa
c. at least 75% of the set pressure of the safety valve
d. the set pressure of the safety valve

Answer 31

c. at least 75% of the set pressure of the safety valve

Question 32

What should Power Engineers carry at all times?

Select one:

a. spare fuses
b. a cell phone
c. a flashlight
d. a small wrench

Answer 32

c. a flashlight

Question 33

With regard to plant operations, the acronym “STAR” stands for

Select one:

a. Stop, Think, Assess, Repeat
b. Stop, Think, Act, Review
c. Start, Think, Assess, Repeat
d. Start, Take readings, Adjust, Review

Answer 33

b. Stop, Think, Act, Review

Question 34

In a multiple boiler high pressure steam plant, when starting an entire system from cold

Select one:

a. Boilers remaining off-line must have their boiler and header stop valves open, and their non-return drain valves shut.
b. The entire system warms and pressurizes as one boiler warms, except for the boilers being left off line.
c. All the boilers are started and warmed at the same time.
d. A small auxiliary heating boiler is used to warm the steam lines while the power boilers are warming.

Answer 34

b. The entire system warms and pressurizes as one boiler warms, except for the boilers being left off line.

Question 35

A power boiler in steam service has a safety valve set to 2000 kPa. What should the maximum operating pressure be for this boiler?

Select one:

a. 1950 kPa.
b. 2000 kPa.
c. 1990 kPa.
d. 1800 kPa.

Answer 35

d. 1800 kPa.

3-12 Table 1

Question 36

One cause of main flame failure in oil fired boilers is:
Select one:
a. Excessive fuel temperature.
b. Excessive purge duration.
c. Excessive furnace temperature.
d. Water in the fuel

Answer 36

d. Water in the fuel

Question 37

When should wet layup be used?

Select one:

a. When a boiler is on standby.
b. For long term storage.
c. When a boiler may be exposed to freezing conditions.
d. When desiccant is unavailable.

Answer 37

a. When a boiler is on standby.

Question 38

ASME VII states that a high-pressure steam plant comprised of a single power boiler may have its boiler and steam lines

Select one:

a. warmed-up at the same time, or independent of each other.
b. interconnected with two other boilers.
c. made of cast iron.
d. drained by the same steam trap.

Answer 38

warmed-up at the same time, or independent of each other.

Question 39

Failure to \_\_\_\_\_ the furnace thoroughly before light-up can cause a furnace explosion.
Select one:
a. preheat
b. soot-blow
c. cool
d. purge

Answer 39

d. purge

Question 40

The main burner test firing valve should be opened

Select one:

a. when taking a fuel sample
b. before starting the main burner
c. when testing the high gas pressure cut-off
d. during a flame-out

Answer 40

b. before starting the main burner

Question 41

Rust in the gauge glass is an indication that:
Select one:
a. The boiler should be blown off.
b. The dissolved solids concentration has peaked.
c. The continuous blowdown setting needs to be increased.
d. Corrosion is occurring in the system

Answer 41

d. Corrosion is occurring in the system

Question 42

The purpose of a boiler boil out is to:
Select one:
a. remove grease and oil from the heat transfer surfaces.
b. determine the level at which the low water cut-off functions.
c. dry out the refractory.
d. clean the fireside surfaces.

Answer 42

a. remove grease and oil from the heat transfer surfaces.

Question 43

On a semi-automatic ignition system, the switch on the supervised cock

Select one:

a. keeps the boiler from pre-purging if the main test firing valve is open.
b. allows the boiler to automatically recycle.
c. keeps the boiler from pre-purging if the pilot test firing valve is open.
d. shuts down the boiler if the main test firing valve is opened during operation.

Answer 43

a. keeps the boiler from pre-purging if the main test firing valve is open.

Question 44

New boilers require a _____________ and a _____________ dry-out before entering operation.

Select one:

a. boil-out, refractory
b. refractory curing, waterside
c. certificate, complete
d. mechanical cleaning, fireside

Answer 44

a. boil-out, refractory

Question 45

To help operators keep track of what step they are at in a procedure, the ___________ method is often used.

Select one:

a. Simplified Startup
b. Call-in
c. Buddy
d. Circle/Slash

Answer 45

d. Circle/Slash

Question 46

Which code contains information on safety valves for high pressure steam boilers?

Select one:

a. ASME Section IV
b. ASME Section I
c. CSA B-52
d. ASME B31.5

Answer 46

b. ASME Section I

Question 47

1 A wide and rapid fluctuation of the water level in a boiler gauge glass may be the result of:
Select one:
a. High dissolved solids concentration in the boiler water
b. A vapour bound boiler feed pump
c. Low alkalinity
d. Low pH

Answer 47

a. High dissolved solids concentration in the boiler

Question 48

If the safety relief valve of a hot water heating boiler is set to open at 207 kPa, the operating pressure should not exceed

Select one:

a. 155 kPa.
b. 207 kPa.
c. 52 kPa.
d. 138 kPa.

Answer 48

d. 138 kPa.

70 kPa or 25% whichever greater differential
207-70=137 kpa
207-(207x0.25) = 155 kpa

Question 49

New refractory in a boiler must be thoroughly dried on low fire
Select one:
a. because high fire uses too much fuel.
b. by operating only the pilot burner.
c. for no longer than one hour.
d. to dry the refractory slowly and keep it from cracking.

Answer 49

d. to dry the refractory slowly and keep it from cracking.

Question 50

If a new boiler is not boiled out correctly, the result may be:
Select one:
a. Refractory damage
b. Excessive waterside corrosion
c. Excessively high water circulation rates
d. Foaming

Answer 50

d. Foaming

Question 51

Standby equipment:

Select one:

a. should never run unless required.
b. should be run on a regular basis.
c. need annual run tests, witnessed by an authorized inspector.
d. require little or no maintenance.

Answer 51

b. should be run on a regular basis.

Question 52

What is foaming

Answer 52

Bubbling in boiler water by high TDS

Question 53

What is priming

Answer 53

Water droplets leave the boiler with steam to the steam line (water hammer) by high TDS

Question 54

What is fouling

Answer 54

the formation of deposit on convection heat surfaces such as superheater and reheater by high TDS

Question 55

Although boilers have many different ignition systems, they all follow the same sequence of steps. Which of the following is the first step?

Select one:

a. Pre-purge
b. Run period
c. Pilot ignition
d. Main burner ignition

Answer 55

a. Pre-purge

Question 56

How should the operating limit pressure control switch on a steam boiler be tested?

Select one:

a. Remove the control from the boiler and test with a pressure source and a master pressure gauge.
b. Jumper the contacts and observe when the boiler shuts off
c. Observe that the boiler cuts in and cuts out during routine boiler operation.
d. Install a new control annually, because the operating limit cannot be easily tested.

Answer 56

c. Observe that the boiler cuts in and cuts out during routine boiler operation.

Question 57

A boiler boil-out
Select one:
a. is done with an alkaline solution. 
b. must be done annually.
c. is done before curing the refractory.
d. is done at 1.5 times the maximum allowable working pressure.

Answer 57

a. is done with an alkaline solution.

Question 58

Cutting steam boilers into a pressurized system is different for heating boilers and power boilers, because

Select one:

a. power boilers do not generally have non-return valves.
b. generally speaking, steam heating systems do not use condensate return systems.
c. steam heating systems are more complex than power boiler systems.
d. steam heating systems may not have all the valves and drains that power boiler systems have.

Answer 58

d. steam heating systems may not have all the valves and drains that power boiler systems have.

Question 59

When warming up a boiler, it should be:
Select one:
a. warmed up quickly so there is not enough time for differential thermal expansion to occur
b. warmed up quickly to prevent flue gas condensation
c. warmed up at a rate of one degree every five minutes, to protect the refractory
d. warmed up at 55 degrees Celsius per hour, to prevent thermal shock

Answer 59

d. warmed up at 55 degrees Celsius per hour, to prevent thermal shock

Question 60

An automatic pressure-relieving device characterized by rapid opening or pop action, or by gradual opening proportional to the pressure increase, and used in vapour or liquid service, is called a

Select one:

a. vapour relief valve
b. safety valve
c. safety relief valve
d. pop valve

Answer 60

c. safety relief valve

Question 61

What is the recommended test frequency for flame safeguard devices?

Select one:

a. daily
b. annually
c. weekly
d. every shift

Answer 61

c. weekly

Question 62

If a cold boiler is warmed up slowly
Select one:
a. it cannot over-pressurize
b. it will develop less stress due to uneven thermal expansion. 
c. the refractory may overheat.
d. condensation will not occur.

Answer 62

b. it will develop less stress due to uneven thermal expansion.

Question 63

As part of a preventative maintenance schedule, duty swaps:

Select one:

a. are seldom performed on boiler feed pumps.
b. involve starting a piece of equipment to record performance data, and then shutting it down again.
c. are performed when another piece of equipment breaks down.
d. distribute wear between regular and standby equipment.

Answer 63

d. distribute wear between regular and standby equipment.

Question 64

When warming up a steam boiler, open the boiler drum vent to

Select one:

a. keep a vacuum from forming in the drum, if the burner trips off.
b. ensure a flow of steam through the superheater banks.
c. permit the release of corrosive dissolved gases, such as oxygen and carbon dioxide, from the boiler water.
d. prevent over-pressurization of the boiler during start-up.

Answer 64

c. permit the release of corrosive dissolved gases, such as oxygen and carbon dioxide, from the boiler water.

Question 65

When locking out a cooled down steam boiler
Select one:
a. close the water column and gauge glass valves, and lock them.
b. close the non-return valve drain, and lock it.
c. open the drum vent, and lock or tag it.
d. open the continuous blowdown valve and tag it.

Answer 65

c. open the drum vent, and lock or tag it.

Question 66

Which is the first step when starting a boiler’s fuel oil system?

Select one:

a. Check for leaks.
b. Check the pressure drop across the fuel filter.
c. Start the fuel pump.
d. Reset the low oil pressure cut-off switch.

Answer 66

c. Start the fuel pump.

Question 67

Which of the following is NOT done prior to start up of a boiler?
Select one:
a. Check the fuel supply
b. Fill the boiler with water
c. Open the blowoff valve
d. Check for a valid operating certificate

Answer 67

c. Open the blowoff valve

Question 68

In many plants, the standby boiler feedwater pump starts automatically when

Select one:

a. the on-line pump fails to provide adequate feedwater pressure.
b. the water level reaches the lowest permissible water level.
c. a low water alarm occurs.
d. the feedwater control valve opens greater than 95%.

Answer 68

a. the on-line pump fails to provide adequate feedwater pressure.

Question 69

Which of the following is NOT a way to maintain a positive pressure on a boiler during a wet layup?

Select one:

a. use a steam blanket.
b. use an oxygen scavenger.
c. use a head tank.
d. use a nitrogen blanket.

Answer 69

b. use an oxygen scavenger.

Question 70

ASME CSD-1 recommends that flame rods and scanners be replaced

Select one:

a. monthly
b. before problems occur.
c. after 5000 hours of operation
d. annually

Answer 70

d. annually

4-18pg.

Question 71

Regarding maintenance programs, what does “PM” stand for?

Select one:

a. Planned Maintenance
b. Plant Maintenance
c. Periodic Maintenance
d. Preventative Maintenance

Answer 71

d. Preventative Maintenance

Question 72

Prior to shutting down a hot water boiler for an extended shutdown:

Select one:

a. Test all operating and limit controls.
b. Shut the boiler off when firing on high by closing the main test firing valve.
c. Start draining the boiler slowly.
d. Raise the pressure to test the safety relief valve.

Answer 72

a. Test all operating and limit controls.

Question 73

For a wet layup, what is the recommended boiler water sodium sulfite residual?

Select one:

a. 40 ppm
b. 10 ppm
c. 200 ppm
d. 50 to 80 ppm

Answer 73

c. 200 ppm

Question 74

What is the recommended boiler water pH for wet layup?

Select one:

a. 12
b. 10
c. 7
d. 7.5

Answer 74

b. 10

Question 75

While warming up and cutting-in a hot water heating boiler with a hot system, which of the following is true?
Select one:
a. Keep the stop valves in the supply and return lines to the boiler closed during warm-up.
b. While warming up, the boiler must be on “high fire” or “automatic.”
c. Close the valves connecting the expansion tank to the on-line boilers, and open the valve that connects the cold boiler to the expansion tank.
d. Make sure the burner shuts off before the safety valve opens.

Answer 75

a. Keep the stop valves in the supply and return lines to the boiler closed during warm-up.

Question 76

Which of the following may cause water hammer in steam lines?

Select one:

a. missing or damaged pipe insulation.
b. opening steam valves slowly.
c. having too many condensate drains open.
d. opening the steam trap bypass valves.

Answer 76

a. missing or damaged pipe insulation.

Question 77

Thermal shock to hot water boilers can be reduced by:
Select one:
a. Installing refractory blanket in the furnace to protect the tubes.
b. Removing soot and ash from the fireside.
c. Preventing the full flow of cool return water into the boiler during the warm-up period
d. Operating with maximum airflow, so that excess heat is carried away in the chimney.

Answer 77

c. Preventing the full flow of cool return water into the boiler during the warm-up period

Question 78

How should the operating limit pressure control switch on a steam boiler be tested?

Select one:

a. Observe that the boiler cuts in and cuts out during routine boiler operation.
b. Remove the control from the boiler and test with a pressure source and a master pressure gauge.
c. Install a new control annually, because the operating limit cannot be easily tested.
d. Jumper the contacts and observe when the boiler shuts off

Answer 78

a. Observe that the boiler cuts in and cuts out during routine boiler operation.

Question 79

Slight smoking when first starting a cold oil-fired boiler
Select one:
a. is caused by too much excess air.
b. is caused by too little fuel pressure.
c. is abnormal, and requires immediate attention.
d. occurs because the furnace is cold.

Answer 79

d. occurs because the furnace is cold.

Question 80

Which of the following is a desiccant used for dry layup?

Select one:

a. Silicone Gel
b. Quick lime
c. Lime soda
d. Soda ash

Answer 80

b. Quick lime

Question 81

When closing up a boiler,

Select one:

a. handhole and manhole yokes must be torqued until the gaskets are compressed to less than 1 mm thick.
b. handhole and manhole gaskets must be coated with sealant, such as graphite paste or silicone.
c. new handhole and manhole gaskets must be used, to prevent dangerous blowouts and costly unplanned boiler outages.
d. handhole and manhole gaskets should be reused, because they are expensive.

Answer 81

c. new handhole and manhole gaskets must be used, to prevent dangerous blowouts and costly unplanned boiler outages.

Question 82

When a combustion air opening is equipped with dampers, the dampers must be

Select one:

a. interlocked with the burner, and fully closed before starting the boiler.
b. interlocked with the burner, and fully open before starting the boiler.
c. partially open, so the burner is not supplied with too much air on start-up.
d. manually closed, to prevent cold air from entering the boiler room

Answer 82

b. interlocked with the burner, and fully open before starting the boiler.

Question 83

Which of the following is NOT done when preparing a steam boiler feedwater system?

Select one:

a. Place the feedwater pre-treatment equipment in service.
b. Verify that the boiler feedwater pumps are in service.
c. Open the feedwater control bypass valve.
d. Confirm that the boiler water level is within range.

Answer 83

c. Open the feedwater control bypass valve.

Question 84

The most important rule in safe operation of steam boilers is to:
Select one:
a. keep the heat transfer surfaces clean.
b. maintain the boiler room log
c. try to keep make-up water to a minimum.
d. keep water in the boiler at the proper level.

Answer 84

d. keep water in the boiler at the proper level.

Question 85

Deaerators often have low-level alarms and low-low level trips:
Select one:
a. in case the boiler feedwater valve fails open.
b. in case the boiler feedwater pumps trip.
c. in case the condensate transfer pumps trip.
d. in case the boiler trips.

Answer 85

c. in case the condensate transfer pumps trip.