Boiler & Pump Operation

Mechatronics Fundamental Boiler Operation

Industrial Maintenance, text and workbook, Boiler Systems Chapter seven, American Technical Publishers 3rd edition, both of them on reserve in the LBCC library. These questions are based on the textbook, lectures, and the pod casts and will serve as the basis for the written test for the course.

Boiler Operation Principles 1. Water expands 1640 time in becoming steam. What problem does this cause? 2. What is boiler? 3. What is steam? 4. What is the heating surface of a boiler? 5. Describe the steam cycle. Fig 7-3 6. Describe the movement of hot water in a hot water heating system. Fig 7-3 7. Define latent heat, sensible heat and superheat. 8. What is the purpose of the feedwater system, the fuel system, the steam systems, and the draft system? 9. What is the standard pressure rating for a low and high pressure boiler? 10.What do we mean by maximum allowable working pressure? What do we mean by maximum working pressure? 11.What is the difference between a firetube and a water tube boiler? 12.What is a boiler pass? 13.What is a packaged boiler?

Fittings & Accessories 1. What is the purpose of a safety valve? 2. What is blowdown in a boiler safety valve? 3. What is wiredrawing and chattering? 4. Who can do repairs or adjustments to a safety valve? 5. Why is a check valve located in the feedwater line? 6. What is the purpose of a globe valve in a feedwater line? 7. What happens if the water column piping becomes clogged?

1 8. List two causes of gauge glass breakage. 9. Where is the NOWL located? 10.Study the steps of gage glass blowdown. 11.How do trycocks help you determine the water level in a boiler? 12.What is the purpose of a boiler vent? 13.What is the purpose of a condensate return tank? 14.Why is feedwater heated before entering the boiler? 15.Why is makeup water required in steam boiler systems? 16.Briefly describe the operation of a float operated feedwater regulator that incorporates a low water fuel cutoff and an on-off boiler control. 17.What is the difference between open and closed feedwater heaters? 18.List two functions of the blowdown valves. 19.What is the purpose of a blowdown tank? 20.How high should the steam gage be able to register? 21.What is the usual purpose of a gate valve? 22.What is the purpose of a steam trap?

Combustion 1. Define complete and incomplete combustion. 2. What conditions are required for complete combustion in a boiler furnace? 3. Define primary air, secondary air, and excess air. 4. Why must combustion be carefully monitored in a boiler? 5. Sketch a label a gas line for a boiler. 6. Why must fuel oil be atomized in a boiler furnace? 7. Describe the basic operation of an on/off control and a modulating boiler control system. 8. Why might a more sophisticated boiler monitoring system be used? 9. Describe the operation of a typical boiler start-up and shut-down sequence of a boiler controller.

2 10.What is the purpose of a flame scanner? 11.Why are flame failures in a boiler furnace dangerous? 12.Describe forced, induced, and combination mechanical draft systems. 13.What is the unit of measurement for boiler draft systems?

Boiler Operations 1. In general what is a normal water level in a gage glass? 2. Study how to blowdown a water column and gage glass. 3. What will you do if you find low water in a boiler? 4. How will you test the low water fuel cut off? 5. How will you check the low water fuel cut off? 6. List the general steps for starting a boiler in a live plant and a cold plant. 7. What is the purpose of a boiler room log? 8. How do you check a safety valve? (try lever test) 9. What boiler conditions must be present when the safety valve is checked? 10. How do you test a safety valve? (pop test) Maintenance Schedule 11.How will you test a flame scanner? Maintenance Schedule 12.How will you test a low gas pressure sensor? Maintenance Schedule 13.How will you test a low draft pressure sensor? Maintenance Schedule 14.What conditions must be present when a boiler is blown down manually? 15.How will a manual blow down be scheduled? 16.What is the difference between surface blow down, continuous blowdown, and bottom blowdown? 17.Study the steps in a manual blowdown. 18.How will a steam trap be tested?

Boiler Water Treatment 1. Why is it necessary to treat even clean looking water before it enters a boiler? 2. What is caustic embrittlement?

3 3. What causes corrosion? 4. What causes foaming? 5. Why is caustic soda added to boiler water? 6. What chemical is added to boiler water to help prevent scale buildup? 7. What chemical is added to boiler water to remove oxygen from boiler water? 8. How are TDS measured in boiler water? 9. How do most small and medium sized operations handle boiler water treatment? 10.How does heating water help condition boiler water? 11.What is hard water and what general ways can it be treated before it enters a boiler? 12.Study the process for replacing a gauge glass.

Troubleshooting Boiler Systems (often emergencies)

1. If you find a boiler that is not firing when it should be what will you do? 2. List four likely causes of a boiler failing to fire. 3. What might cause flame failure in a gas fired boiler? 4. How will you handle a low water situation that shuts down a boiler? 5. How will you handle a boiler with a blown tube that is one of several boilers? 6. How will you handle a boiler that is still firing with no water visible in the gauge glass? 7. How will you handle high water in a boiler? 8. What is a furnace explosion? 9. How will you handle a boiler that is still firing even though it is over the pressure that the safety valve should have opened, but the valve is not open? 10.Describe the general process for preparing a boiler for an annual inspection? 11.What is the difference between a wet and dry lay-up?

4 Oregon Boiler Web Links

Boiler License Requirements http://www.bcd.oregon.gov/programs/boiler/boilerlicensingrequirements .html

Boiler Maintenance and Operation http://www.cbs.state.or.us/external/bcd/programs/boiler/boiler_notice.ht ml#links

Oregon Boiler Law http://www.cbs.state.or.us/bcd/programs/boiler/boiler_laws_and_rules.p df