Part B - Paper 1

1. A firetube boiler has been prepared for inspection, what should you look for on
the:

Furnace entry refractory - The refractory should adequately protect the

end of the tube where it is in the front smoke box section and not cooled
by water on its outside surface.

Water side - Examine the water side through all the handhole doors for
tube pitting, scale build up, or oily deposits. Oil deposits on tubes will lead
to local overheating and failure.

Fire tubes - Examine the inside of the tubes with a flashlight for signs of
moisture due to thinning and pitting of the tube from the water side
corrosion.

2. Explain the advantages of firing pulverized coal over other methods of firing
coal.
Low grade lignite and sub-bituminous coals can be burned satisfactorily.
Better mixing of the coal fuel and combustion air, therefore less excess air needed.
Superior combustion control.
Name three types of pulverizers.
Roll Mill, Bowl Mill, Ball Race Mill, Tube Type Ball Mill
3. Explain how you would replace a broken gauge glass.
1. Isolate gage glass
2. Open gage glass drain valve.
3. Unscrew the nuts and remove the broken gage glass and washers.
4. Open gage valves to blow out any fragments of glass. Close valves.
5. Cut new glass to length using glass tube cutter.
6. Place nuts and new washers on gage glass and install into position. Hand tighten.
7. Warm up glass by cracking steam valve. Close drain valve.
8. Crack open water valve. When water level in glass stabilizes open steam and
water valves fully.
What is the purpose of a water column and gauge glass?
To accurately indicate the level of water in the boiler to the boiler operator.
The water column dampens level fluctuations, collects sediment, and provides a place
for the try cocks.

4. You are in charge of a large gas fired power boiler with a superheater and
reheater, automatic combustion control, and a forced draft fan. Explain what
you would do and the reasons why it could happen if:

There is a flame failure - Causes of flame failure could be interrupted

fuel supply, tripped by another safety device (i.e. low water, high pressure, etc),
faulty combustion controls.
The fuel supply to the burner should be shut off immediately, and the furnace
purged. Investigate cause of flame failure to determine length of outage. Take care
of steam supplied devices (turbines, processes, etc) accordingly.

There is a low drum water level - Causes of low water level could be
faulty water column/gage glass, tube leak, faulty feedwater controller, faulty
pump, blocked feedwater pipe (valve closed), IBD valves open, sudden stop in
steam demand (shrinkage).
First prove proper gage glass indication, if water level proves low, immediately
shutdown the burner and investigate cause. Take care of steam supplied devices
(turbines, processes, etc) accordingly.

5. Describe a Zeolite Softener and what it does.

The sodium zeolite softener uses ion exchange to convert scale-forming salts, in the
water, to non-scale forming salts. The zeolite in the softener removes calcium and
magnesium cations from the water and replaces them with sodium cations. When the
zeolite has given up all its sodium cations it is regenerated.
What do you watch for during normal operation?
During normal operation the water leaving the softener should be tested regularly to
ensure all the hardness is removed from the water. If hardness is detected, then the
zeolite bed is exhausted and needs to be regenerated.

6. Sketch a block diagram of a low pressure return line trap heating system

What is the use of the trap?

The return trap is used to force condensate back into the boiler using steam pressure.
This allows the boiler to be operated up to 100 kPa without requiring an equivalent
static head to force the condensate back into the boiler.

7. Welding Definitions:
1)

Braze - Where a weld joint is produced by heating to above 430oC and by

using a non-ferrous filler metal, which has a melting point below that of the
metals being brazed together.

2)

Flux - Substance used to prevent or remove oxides and impurities from the
braze weld, or blacksmiths weld.

3)

Porosity - Gas pockets or voids trapped in the weld during the welding
process

4)

Coated Electrode - Covered electrode consisting of a rod with heavy or light

covering to protect the molten material from the atmosphere and to stabilize the
arc.

5)

Slag Inclusion - Non-metallic material entrapped below the surface of the

weld.

6)

Submerged Arc Welding - An arc welding process where the welding occurs
beneath a protective layer of granular and molten mineral material. This is
normally an automatic process that produces seams which are neat and uniform in
appearance.

7)

Machine Welding - Welding with equipment that performs the operation,

under control of a trained operator

8)

Downhand - Welding is performed from the upper side of the joint. The weld
face is approximately horizontal

9)

Weave Bead - A weld bead made with transverse oscillation of the rod

10)

Undercut - A groove melted into the plate at the toe or side of the weld

11)

Toe crack - A crack in the plate at the edge of the weld

12)

Oxy-acetylene Cutting - An oxygen-cutting process wherein the cutting of

metal is caused by the chemical reaction of oxygen with the base metal at high
temperatures. High temps created by burning acetylene with oxygen.

13)

Shielded Metal Arc Welding - Shielding of the weld from the atmosphere is
obtained from the decomposition of the electrode covering, due to the heat of
welding.

14)

Preheating - Heating the base metal immediately before welding to slow the
cooling rate of the weld and prevent cracking

15)

Residual Stress - Stress remaining in a structure, as a result of welding

16)

Spatter - Metal particles sprayed out during electric resistance welding

8. Sketch and describe a Magnetic Low Water Fuel Cutoff Switch.

At normal water levels, the permanent magnet attached to the pivoted mercury switch
is drawn toward the magnetic plunger. This causes the mercury switch to tilt to the
right and the mercury inside closes the burner on circuit. When the water level drops
to the point that the magnetic plunger is no longer in the permanent magnets magnetic
field, the tension spring pulls the magnet away from the tube and causes the mercury
switch to tilt to the left. The mercury inside the switch moves to the left side thus
opening the burner circuit, closing the alarm circuit and shutting off the gas supply.
Explain 2 wire and 3 wire configuration, and the operation of the mercury
switch.
A 2 wire mercury switch and a 3 wire mercury switch are used on a combination low
water cut-off and pump control device. The 3 wire switch is the low water cut-off,
used to interrupt the burner circuit and close an alarm circuit. The 2 wire switch is
used to start and stop the boiler feed pump to compensate for fluctuating water levels.
The mercury switch is a small glass bulb under vacuum which contains a small
amount of mercury. Contacts are mounted inside the bulb on one or both ends. These

contacts are connected to external wiring and circuits. When the bulb tilts from one
side to the other the mercury inside opens and closes the circuits as it moves back and
forth.

9. Sketch and describe 2 Element Feedwater Control, and explain its advantages
over 1 element control.

The advantage of a 2 element feedwater control is that the added steam flow sensor
allows the effects of swell and shrinkage to be minimized. When an increase in steam
demand is realized the steam flow sensor overrides the drum level sensor and the
controller increases the feedwater flow to the drum. Conversely when a decrease in
steam demand is realized the steam flow sensor causes the controller to decrease
feedwater flow to the drum. When steam demand is stabilized, the drum level sensor
takes over again to make the final adjustments on drum level.

10. Explain the operation and way of testing the following:

High Pressure Limit Switch - If for any reason the operating control for
normal operation fails to shut down the burner when the cut-off point is
reached, the high limit control will open the burner circuit and the fuel valve
will close.
Testing of this switch cannot be done during normal boiler operation. To test
the high limit switch, the power to the boiler controls is disconnected and a
test lead is placed across the terminals of the operating control. Power is
reconnected to the controls and the boiler fired up. The boiler is fired until the
pressure reaches the high limit setting, at which time the limit switch should
open the burner circuit and shut down the boiler. Once test is complete
disconnect power to controls and remove test lead from the operating control.
The boiler may no be put back into normal operation.

Low Fuel Pressure Switch - Consists of a diaphragm which has gas pressure
acting on one side and an adjustable spring force on the other. When gas
pressure is at least at the minimum required for stable burner operation the
diaphragm actuates a switch to complete the burner circuit. If the gas pressure
drops below minimum, the spring pressure overcomes the gas pressure and the
diaphragm opens the burner circuit thus shutting down the burner.
To test this switch during normal operation, the main gas cock is slowly
closed until the pressure falls below the minimum limit and the burner is shut
down. The pressure at which the burner cuts out is recorded.

Low Air Pressure Switch - This switch works on the same principle as the
low fuel pressure switch. If the amount of air supplied to the burner drops
below the minimum required for safe combustion, the spring pressure
overcomes the air pressure and the diaphragm opens the switch and shuts off
the fuel supply.
To test this switch, controls should be in manual. A test light with a power
source is connected to the terminals of the control. With the burner damper
wide open and the fan in operation, slowly restrict the air intake to the fan
until the test light comes on and record your observations.

11. Describe the procedure for taking a water tube boiler off line and preparing it
for inspection and the safety precautions involved.
1) To properly shut down the boiler the load is reduced to 50% and the sootblowers
are operated to clean the fireside surfaces as much as possible. Firing rate is reduced
to minimum and the controls are set to hand control. The boiler is then shut off.
2) Once the boiler has cooled slowly with air dampers shut and the pressure has
dropped to 70 kPa, open the drum vents.
3) The boiler is now isolated by closing and locking all valves and opening and
locking all circuit breakers which may allow any gas, liquid, or solid to enter the
boiler, or could cause motion of equipment within the boiler. All the valves and
breakers isolated and locked are now tagged with DO NOT OPERATE tags and a
list is made to ensure all tagged equipment is accounted for when the tags are
removed in preparation for startup. Only the person in charge may remove these tags.
4) Once the boiler water has cooled to about 90oC, open the blowdown valves and
drain the boiler.
5) Open the steam drum manhole first, then the mud drum manhole. This is to
prevent the steam drum fro pressurizing due to the circulating effect.
6) With the blowdown valves wide open, flush out the boiler with a high pressure
water hose. Allow to drain completely then close and tag out the blowdown valves.
7) Open the fireside access door.
8) Provide PPE where necessary, and ensure any electrical power used within the
boiler is transformed to 12V to eliminate the danger of electrocution to personnel.
12. Describe the startup procedure for a gas fired firetube packaged boiler that has
been shut down for the summer.
1) Check inspection certificate and maintenance record for recent repairs.
2) Do a walk around the boiler, checking for water leaks and cleanliness of boiler
area.
3) Check gauge glass for proper water level and confirm using try cocks. Ensure
water column and gauge glass valves are fully open and drains closed.
4) Ensure air vent is open.
5) Open the steam line drains and open the header steam valve and then open the
non-return valve.
6) Ensure the safety valves are sealed and not tampered with.

7) Open the main gas cock at the furnace front, ensuring the handle is pointed
correctly in line with the hole in the valve plug.
8) Open the pilot gas cock. Observe pilot and main gas pressure regulators, limit
switches, gas line valves, etc
9) Check for correct position of the feed pump valves, condensate return valves,
makeup valves, etc. open the feedwater inlet valve on the boiler. Check and
replenish chemicals for feedwater as required.
10) Observe the high steam pressure fuel cut-off setting and the steam pressure
control settings
11) Check that the cable is connected from the ignition transformer to the igniter
plug, and that the flame scanner is in place
12) Check the connection of the sensing line from the forced air chamber to the
low air pressure fuel cut-off switch. Ensure air inlet screen is free of debris
13) Check that the boiler start switch is in the off position, then close the feed
pump breaker and boiler main power breaker
14) Actuate the boiler start switch, if boiler does not start reset all the safety
switches - low water, high gas, low gas, etc
15) Once the boiler is firing and steam starts to blow, close the air vent
16) Blow down the water column and gage glass
17) Once the boiler is up to 75% normal working pressure, operate the safety
valve try lever for one short blow and one long blow to ensure it reseats
properly
18) Perform a test on the low-water fuel cut-off switch. The burner should shut
down with 1 inch showing on the gage glass. Blowdown the low water cut-off
drain to clear any sediment. Once boiler feedwater pump is reenergized,
observe the drum level control shuts off the pump at about half glass.
19) Once the boiler and steam lines are fully warmed up, close any drains that are
not controlled by a steam trap.
20) Check that the boiler handhole and manhole doors are tight
21) Observe the condition of the flame, should appear blue. Check the stack gas
temperature.
22) Check and tighten up any gland leaks showing on the valves
23) Enter startup time, on header time, and chemicals added in log book
24) Take a boiler water sample to ensure it is within proper limits as to chemical
content.

13. Describe the procedures for starting an FD fan on a high pressure boiler.
1) Check the fan and driver area as well as the inlet screens for debris.
2) Perform a thorough visual inspection of fan and driver components.
3) Check the dampers and damper drive connections for tightness
4) Check the oil in the fan and driver bearings, fill or change oil if needed
5) Turn on cooling water to bearings.
6) Start fan, listen for any unusual noises, and check for vibrations of fan casing and
bearings. Look for any oil leaks. Once fan has ran for a while check bearings for
temperature.
Give 2 reasons why an ID fan is larger than an FD fan.
1) The ID fan removes more mass because the flue gas consists of the mass of the
fuel plus the mass of the air.
2) The volume of the gases is larger due to the temperature difference
3) The ID fan handles any leakage into the boiler setting.
Discuss 5 routine inspections on FD fans.
1) Look for leaks of oil, water, and air. Look for any unusual condition
2) Listen for unusual noises, note any unusual smells like hot bearings, motor
shorts, leakage of gases, etc
3) Check oil levels and rotation of bearing oil rings. Check bearing temperature
and vibrations
4) Check fan and driver indicators like vibration, temp, pressures, etc
5) Generally look for any unusual condition, a change normally indicates
problems
14. Why is it important that the steam leaving a steam drum be dry?
All moisture must be removed from the steam to prevent any impurities being carried
over with the steam. These impurities will form deposits in the superheater tubes and
overheating of these tubes will result. Also if a steam turbine is used these impurities
will form deposits on the blades and turbine control valves and cause damage.
Explain why on some high pressure boilers feedwater is sprayed into the steam
before it leaves the steam drum.
This causes a portion of the leaving steam to condense. The condensate formed
absorbs any gaseous impurities present in the remainder of the steam.

Describe 2 methods of removing moisture from the steam in the drum.

1) Cyclone type separator - causes the steam to acquire a whirling motion and
the moisture droplets are thrown out of the steam by centrifugal force.
2) Scrubber type separator - consists of a number of closely spaced corrugated
plates between which the steam passes with the moisture droplets depositing
upon the plates.
15. Sketch and describe a Volute centrifugal pump and a Diffuser centrifugal pump.

A volute pump consists of an impeller made up of a number of vanes, which rotates in

a volute stationary casing. The volute casing is one that increases in cross-sectional
area from the impeller to the outlet. Liquid is drawn into the center of the impeller
and by centrifugal force is accelerated to a high velocity and discharged into the
casing. As the liquid travels through the volute casing the velocity energy is converted
to pressure energy. A low pressure area is created at the impeller eye as the liquid is
forced outward, thereby drawing in more liquid and creating a constant flow.
A diffuser pump consists of an impeller like the volute pump, but also has a stationary
diffuser ring. As the high velocity liquid leaves the impeller by centrifugal force it
passes through the diffuser vanes. The diffuser vanes gradually increase in area and
convert the fluids velocity energy into pressure energy. The fluid is then discharged
into the casing. Some diffuser pumps have a volute casing as well which serves to
increase the pressure even further.
Describe two ways to stop end thrust.
Double inlet impeller - balances the forces on the impeller, although a light thrust
bearing is still required.
Opposing single-inlet impellers - used on multistage pumps with single inlet
impellers. The inlets of one half of the impellers face one direction and the other half
face the other direction thereby counteracting each others axial thrust.

16. Sketch and describe 5 different rotary pumps.

External gear pump - two gears rotate in opposite direction inside the casing. Liquid
is drawn in and trapped between the teeth and the casing as it travels around the
casing and is discharged out the inlet.
Internal gear pump - an external cut gear meshes with an internal cut gear on one side
and is separated by a crescent shaped partition on the other to prevent liquid from
passing back to the suction. Liquid fills the spaces between the teeth as they unmesh,
and is forced out the discharge when they mesh again.
Sliding vane pump - has an off center mounted rotor with slots containing sliding
vanes. The vanes are forced out by centrifugal force to seal against the casing wall. As
the fluid is drawn in due to the increasing area of the rotor to the casing, it is trapped
by the vanes and carried around to the discharge where the rotor-casing area is
reduced thereby forcing the liquid out the discharge.
Three lobe pump - same as external gear pump only lobes instead of gears
Two screw pump - has two opposing spiral rotors. Liquid is carried from the inlet to
the discharge as the spirals rotate and mesh.

17. Sketch a steam drum showing all internals and flows.

Describe the flow of steam and water in the drum.

The steam/water mixture from the risers enters the drum behind a baffle and then
enters the cyclone separator at the side. The water, thrown out by centrifugal force,
drains from the bottom of the cyclone below the drum water level. The steam leaves
the top of the cyclone and passes through the chevron drier to remove any residual
moisture, before leaving the drum.
Feedwater enters through the feedwater distribution pipe or pipes which run the
length of the drum for uniform distribution. The water makes up the drum level and is
used as needed by the boiler as the water circulates down the downcomers and to the
generating tubes.

18. What are the types of blading on an FD and ID fan?

1)
2)
3)
4)
5)

Airfoil - FD
Backward-curved - FD
Straight radial - ID
Radial tip - ID
Forward curved - ID

Describe 3 methods of fan output control.

1) Inlet damper control - using inlet vanes to control the airflow through the fan.
2) Outlet damper control - throttling the airflow from the fan
3) Variable speed control - varying the driver speed through variable frequency
drives or by using fluid drives, magnetic couplings, or steam turbines
Sketch a balanced draft boiler

Balanced draft boiler

19. List 5 reasons for black smoke.

Too much fuel supplied
Not enough oxygen supplied
Furnace temperatures not high enough
Not enough combustion time
Not enough turbulence in the furnace
What causes black smoke?
Insufficient oxygen combined with the fuel to provide complete combustion, thus
creating CO and unburned carbon particles.
When it is cold outside, you see white smoke, what is it?
Water exiting the stack as wet steam. Normally invisible superheated steam on warm
days.
What happens when scale forms in the tubes?
When scale forms in the tubes it acts as insulation between the water in the tubes and
the radiant heat from the furnace. This leads to poor heat transfer and may cause
overheating of the tubes. Scale also provides a place for caustic corrosion to take
place.
How do you remove the scale?
Scale can be removed by either using mechanical or chemical cleaning methods.
Mechanically, various tools and air driven equipment are used to physically remove
the scale from the tubes, usually used only on firetube boilers and small watertube
boilers. Large watertube boilers (steam generators) use the chemical cleaning method
which involves an inhibited acid cleaning. Scale can be prevented from forming by
proper water treatment.

20. How does a vent condenser work?

A vent condenser uses water to condense the steam carried by the venting gases either
by direct contact or using a heat exchanger method.
What are the differences between an internal and external vent condenser
An internal vent condenser has the cooling water come into direct contact with the
leaving steam in the form of a spray. Internal vent condensers are located within the
deaerator shell. The condensate and water mix and drain into the deaerator storage
area.
An external vent condenser has the cooling water running through tubes and the
steam passes over the tubes and condenses. The water does not come into direct
contact with the steam. The condenser is located outside of the deaerator shell. The
condensate drains back into the deaerator.
List 4 sections of a Deaerator
1) Heating section
2) Scrubbing section
3) Storage section
4) Vent condenser section
What is the difference between a spray type and tray type deaerator?
Spray type deaerators have the water enter the deaerator through spray valves and is
therefore in a finally divided state. The water is heated by the steam in the heating
section and then passes to the scrubber section where the gases are released by
coming in contact with the entering steam. The deaerated water flows to the storage
area and the gases flow to the vent condenser where any entrained steam is
condensed.
Tray type condensers work much the same except instead of the water passing
through spray nozzles, it is broken up by trickling down over a series of trays. The
entering steam scrubs the water in the lower tray section and heats the water in the
upper tray section. The released gases and entrained steam flow to the vent
condensing section where the steam is condensed and the gases flow out the vent
opening.

21. What are the advantages and disadvantages of hot water heating compared with
steam heating?
Advantages:

Boiler and piping is smaller

Piping pitch or slope not as critical

Changing system temperature more easily

Less maintenance costs

Disadvantages:

Must run at higher pressures in multistory buildings if boiler in basement

More power required to circulate the water

Greater danger of damage due to freezing

More damage caused if leak develops

What are 2 different types of heating system control?

Intermittent circulation method and Continuous circulation method, described below.
What are the differences between continuous and intermittent flow systems?
Intermittent Circulation - This method keeps the boiler water temperature at a
constant value by an immersion thermostat (aquastat) which controls the operation of
the burner. The circulator is controlled by a thermostat located in the heated zone.
When the air temperature drops below the desired setting, the thermostat starts the
circ pump thus supplying hot water to the convectors. Once desired temperature us
reached the thermostat shuts off the pump.
Continuous Circulation - This method keeps the circulation constant, and the
thermostat controls the temperature of the supply water by manipulating burner
operation.

22. Pump Definitions:

1) Static Suction Lift - The vertical distance from the liquid supply level to
the pump centre line when the pump is above the supply source.
2) Static Suction Head - The vertical distance from the liquid supply level to
the pump centre line when the pump is below the supply source.
3) Static Discharge Head - The distance from the centre line of the pump to
the free surface of the liquid in the discharge tank.
4) Total Static Head - Discharge head - Suction head or Discharge head +
Suction lift
5) Friction Head - Pressure, expressed in meters of head, required to
overcome the effects of friction in the piping system
6) Velocity Head - Pressure required to give the liquid its motion through the
system at a given velocity
7) Pressure Head - Pressure in a closed vessel from which the pump takes
its suction or against which the pump discharges
8) Dynamic Suction Lift - The sum of static suction lift and suction friction
and velocity head
9) Dynamic Suction Head - Static head - suction friction and velocity head
10) Dynamic Discharge Head - Static discharge head + discharge friction and
velocity head
11) Total Dynamic Head - Dynamic suction lift + Dynamic discharge head or
difference between Dynamic suction and discharge head.
12) Vapor Pressure - Pressure created by the vapors of a liquid at their free
surface. Pressure at which the liquid will flash to vapor. Flashpoint
pressure increases with increase in liquid temperature. Suction pressure
must be greater that vapor pressure to prevent liquid from flashing to
vapor.
13) Cavitation - Cavitation occurs when the pressure at any point inside the
pump drops below the vapour pressure of the liquid. This causes vapour
bubbles to form and create cavities in the liquid flow. These bubbles are
carried along with the fluid until they reach an area of higher pressure
where they collapse back into the fluid and produce a shock wave. This
resulting shockwave damages the metal surfaces by gouging out small
pieces. Rapidly reoccurring cavitation results in vibration and noisy
operation

14) Net Positive Suction Head (NPSH) - Net positive suction head is the
liquid pressure supplied to the pump suction in excess of the vapour
pressure. This ensures the suction pressure will always be greater than the
vapour pressure of the liquid.
15) Slip - The difference between the actual volume of liquid discharged by
the pump and its theoretical capacity. Slip is caused by leakage past valves
and pistons in reciprocating engines and the stationary and rotary members
of rotary pumps.
16) Volumetric Efficiency - The ratio of actual volume discharged to the
theoretical capacity of the pump. Expressed as a percentage of theoretical
capacity

23. Describe 5 factors that affect the life span of boiler furnace refractory.
1) Furnace operating temperature too high
2) Firing with incomplete combustion, CO attacks hot surface of the brick
3) The amount of solids carried in the combustion gases, abrasive action
4) The amount of fluid slag developed in the furnace, eats away at brick
5) Constant drastic temp changes, expansion and contraction, from start and stop
Describe the procedure for boiling out a boiler. Identify the chemicals that are
used.
Boiling out a boiler removes any grease, oil, or other contaminates from the internal
waterside surfaces of the boiler. To carry out this procedure chemicals are dissolved
into the boiler water. The boiler is then started and the pressure is raised to about one
third normal pressure and maintained for a specified amount of time. All drains are
blown at regular intervals. The chemical mixture in the water will dissolve any
deposits on the tube surfaces and the drum internals. Chemicals that are used are 2 kg
each of soda ash, tri-sodium phosphate and caustic soda per 1000 kg of water
contained in the boiler.
24. Sketch and describe a method of combustion control suitable for a high pressure
water tube boiler. The sequence of events must be clearly described.
See Question 55

25. Define 4 advantages and 2 disadvantages of mechanical draft compared to

natural draft.
Advantages:
1) Better control of airflow
2) Allows use of superheaters, economizers, and air heaters, increased efficiency
3) Smaller less expensive stack can be used
4) Better fuel/air mixing, higher heat output per size of furnace
5) Better purging of furnace, safer operation
6) Draft produced independent of atmospheric conditions
Disadvantages:
1) Initial cost higher
2) Closer supervision necessary, more mechanical equipment involved
3) More unit outages because of equipment breakdowns.
List 3 factors which influence the power required to drive a fan.
1) The amount of air or gas to be moved in a unit time
2) The pressure difference across the fan
3) The efficiency of the fan and its drive
Explain why performance curves are required for fans.
A performance curve is required in selecting a fan for any purpose since each fan has
its own performance curve which defines exactly how the machine will perform.
What 4 quantities are shown on a typical fan performance curve chart?
1) Efficiency
2) Power
3) Pressure
4) capacity

26. Describe the correct procedure for starting up a balanced draft, gas-fired watertube boiler and put it on line with a battery of boilers already in service.
1) Perform pre-checks on boiler and auxiliary equipment. This includes water
sample, deaerator level, stroking all control valves, FD and ID fan checks and
proper damper control, fuel pressure, make sure drum vent is open and all
permissives are met.
2) Start ID fan then FD fan
3) Pre-purge the furnace
4) Reduce air flow and light the pilot
5) Light main burner and ensure a stable flame
6) Keep flame low to provide for a slow controlled warm-up, may test LWFCO
7) Once steam emits from the vent, close vent
8) As the boiler starts to build pressure warm up the steam line between the main
stop and the header. This is done by opening the drain at the main stop and
cracking open the header valve to allow the header steam to flow back to the
main stop and out the drain. Slowly open the header valve wide open once the
pressure has equalized between the header and steam line.
9) Once boiler pressure is slightly below header pressure back of the main stop
spindle about the way.
10) Once boiler pressure exceeds header pressure and the disc piston opens,
slowly open the main stop the rest of the way and close the drain. The boiler is
now on line.
Describe the correct procedure for taking this boiler out of service.
1) Give the boiler a good blowdown
2) Put controls in hand and slowly reduce firing rate. Ensure other boilers on the
header take up the required load. Main stop will close once header pressure
exceeds boiler pressure.
3) Once firing rate is reduced to minimum, shut off the main fuel or test LWFCO
to trip the boiler.
4) Allow the fans to post purge for the determined time then shut down the FD
fan then the ID fan.
5) Close the header stop valve
6) Open drum vent once boiler pressure drops to slightly above atmospheric to
prevent a vacuum forming in the drum. Boiler is now shutdown.

27. Define the following boiler repair terms:

Arrow head bit - Cutter bit with arrow shaped cutting edges for drilling out
plugged or heavily scaled, straight, heat exchanger tubes.

Over rolling - Excessive tube expanding - work hardens tube metal, causes
flaking and induces stress fatigue. Shortens tube life. The expanded part of the
tube is beyond the drum thickness.

Tube belling - Flaring of a tube end.

Controlled rolling - Expanding tubes utilizing a portable motor that will

sense torque and stop rotation of an expander when a specified torque or
tightness of the tube is reached.

Oyster knife - A chisel shaped tool operated by impact. Used to collapse a

boiler tube inward by being forced between the tube end and the drum.

Wall reduction - The thinning of a tube wall when tube expanding.

Fish tail - (whips) Flexible wire type of holder used between the motor and
cleaning accessory.

Rattler (vibrator) - A device rotated by an air motor that causes vibration

inside the firetubes to remove the external scale from the tubes.

Insert - Short length of tube, inserted into an end of an air preheater tube to
attempt the salvage of the unit without complete tube replacement.

Serrating tool - A tool for cutting grooves or serrations on the inside of a tube
sheet hole.

28. Describe the principle of operation of 2 types of automatic air vents used on hot
water heating systems.
1. Float operated air vent - with water present in the vent body the float will hold the
vent valve shut. When air enters the vent body the water level drops and the float
drops thus opening the vent valve.
2. Hygroscopic disc vent - when water is in contact with the disc it will swell and
seal off the air vent. When air enters the vent, the disc will dry out and shrink thus
opening the vent port.

With the aid of a sketch, describe the operation of a diaphragm air vent.

The sealed cylinder attached to the needle valve is filled with a volatile fluid. When
steam surrounds the cylinder, the volatile liquid vaporizes and a pressure is produced
within the cylinder. This forces the diaphragm out against the stop beneath it causing
the cylinder and needle valve to rise and the port is shut off preventing steam from
escaping. When air enters the vent the volatile liquid will not be vaporized due to the
lower temperature. This causes the diaphragm to collapse and the cylinder and needle
valve move downward opening the port to allow the air to escape.

29. The 2 types of sootblowers are stationary and retractable. Explain where each
type is installed and explain why that type is selected.
Stationary soot blowers are installed in the lower temperature zones of the boiler such
as the economizer and air heater sections. The temperatures do not get severe enough
in these areas to damage the sootblower if it is left in.
Retractable sootblowers are installed in the high heat areas of the boiler such as the
superheater and reheater sections and the furnace walls. The temperatures in these
zones are too high, so the sootblower must be retracted when not in use to avoid
overheating.
Explain 4 precautions to be taken to ensure maximum sootblower and boiler
tube life.
1) Boiler load is at least 50% maximum capacity so fine dust is removed quickly
2) Ensure induced draft is increased until furnace pressure is 7 mm water gauge
above normal. To prevent blowback through openings.
3) Do not allow traversing or rotating sootblowers to remain in one position and
impinge directly upon tubes or baffles while discharging steam, as the steam
will erode the tubes and a leak may result.
4) If air is used it must be dry, if steam is used it must be superheated
Describe the procedure for manually soot blowing a high pressure water tube
boiler burning pulverized coal. The boiler is fitted with a superheater,
economizer and an air heater.
Ensure boiler load is at least 50% and increase induced draft so furnace
1)
pressure is 7mm water gauge above normal. Then close isolating cocks on
draft indicators and CO2 sampling points.
Clear all dust and ash hoppers
2)
Open drain valve on main steam supply header to remove any condensate
3)
Crack open the main-steam supply header isolation valve, when all
4)
condensate removed close drain and fully open isolation valve.
Close all boiler inspection windows
5)
Operate each sootblower individually beginning with those nearest the bottom
6)
of the furnace and working systematically towards the rear of the boiler unit
Open and close the steam stop valve on each sootblower immediately before
7)
and after the blower is used
Make sure that retractable sootblowers are fully traversed into the gas pass
8)
before opening the steam stop valve, and they are fully withdrawn
immediately after use
Once soot blowing cycle has completed, close the main steam header isolation
9)
valve
10) Adjust draft back to normal conditions
11) Clear all dust and ash hoppers
12) Open isolation cocks for draft and CO2

30. Define the following water treatment terms:

Turbidity - Particles of suspended matter in water

Colloidal particles - Very small particles of insoluble material suspended in

water

Deionization - The removal of harmful ions from a solution using an ionexchange process. Also known as demineralization

Coagulation - The process where finely divided particles of turbidity are

combined by chemical means into masses sufficiently large to settle out of
suspension.

Floc - A spongy substance produced from the addition of a coagulant to water

containing particles of turbidity. The product of coagulation. The floc has a
large surface area which traps fine suspended particles in the water, thus
forming larger particles.

With the aid of a sketch, explain the operation of a coagulating water clarifier.

The raw water and the coagulant enter the top of the clarifier and are mixed together
by agitators. As the mixture travels down the mixing zone of the clarifier the particles
coagulate. The coagulated particles form a sludge blanket in the bottom portion of the
upflow zone effectively acting as a filter for the upflowing water. The clarified water
is collected at the top of the upflow zone by a collector pipe. The sludge collects in
the conical section at the bottom and is removed by periodically opening the
desludging valve.

31. Describe the differences between two types of mechanical seals.

Rotating Mechanical Seal - has the mating ring held stationary in the pump housing
and the sealing ring held by a shell secured by set screws to the shaft turns with the
shaft.
Stationary Mechanical Seal - has the shell containing the sealing ring held stationary
in the pump housing and the mating ring is fastened rigidly against a shoulder to the
shaft, so that it rotates with the shaft.
Define 4 advantages of mechanical seals
1) They require much less maintenance
2) They do not produce wear of the shafts or shaft sleeves as does packing
3) They reduce leakage to a minimum
4) They can work under very high temperatures and pressures
Define 2 disadvantages of mechanical seals
1) Greater first cost
2) When seal fails, greater downtime to replace seal than packing
Sketch a mechanical seal and explain how it operates

A stationary mechanical seal contains springs and a sealing ring which is held
stationary in the annular space of the pump housing. The mating ring, which is
mounted to the shaft against a shoulder, rotates with the shaft. The sealing ring is
forced against the mating ring by the springs thereby preventing leakage between
them. O-rings are installed between the sealing ring and the shell and the mating ring
and the shaft to prevent leakage.

List 4 causes of leaking in mechanical seals.

1) Seal faces are scored or grooved
2) Distortion of the rings due to unevenly tightened bolts of the seal housing
3) Excessive pumpshaft vibration
4) O-rings or other gaskets nicked during installation
5) Misalignment of piping resulting in distortion of pump parts

32. Define packaged boiler

A boiler supplied complete with burner, draft fan, feed pump, controls and other
accessories by the boiler manufacturer.
Sketch and describe a 4 pass firetube boiler showing the water level, flue gas
flow, water flow, and all fittings.

33. What is the chemical composition of acetylene?

92.3% Carbon and 7.7% Hydrogen gravimetric. C2H2
What measures are taken to enable safe storage of acetylene in a cylinder?
The acetylene cylinders are initially packed with a porous filler to which acetone is
added. The acetone will absorb 25 times its volume of acetylene per atmosphere of
pressure. The acetylene that is dissolved into the acetone is also divided up into cells
within the cylinder. This stabilizes the acetylene.
What is the purpose of the fusible plug on an acetylene cylinder?
To release the combustible gases slowly instead of causing a violent exploding in the
event that a cylinder is caught up in a fire.
At normal temperatures, what is the storage pressure of acetylene?
1700 kPa
What is the difference between the threaded hose connection on an acetylene
cylinder and the threaded hose connection on an oxygen cylinder?
The acetylene connection has left hand threads and the oxygen connection has right
hand threads
What is the storage pressure of oxygen at normal temperatures?
15000 kPa
What is the significance of the number stamped on an oxy-acetylene torch tip?
The number indicates the pressure in psi required from both the acetylene and the
oxygen. For example a number 2 tip requires 2 psi acetylene and 2 psi oxygen

34. Sketch and describe a single element feedwater control

With single element feedwater control a differential pressure transmitter senses a

change in head pressure in the drum due to the water level. When a change in level is
detected, it is compared to the set point in the controller. If any deviation from set
point is detected, the controller output will reposition the feedwater control valve
accordingly to compensate.
Sketch and explain water hammer
Water hammer is a series of shocks produced by a sudden change in velocity of water
or condensate flowing through a pipeline. This can be caused by the sudden starting
and stopping of water flow. Another way water hammer is produced is by steam being
admitted to a pipe containing water or condensate. The steam will pass above the
surface of the water and create a steam pocket behind the water. As the steam rapidly
condenses a vacuum will be formed in the pocket. The water will rush in to fill the
void and produce water hammer.
Explain how water hammer is prevented.
To prevent water hammer, all water and condensate should be drained from any
piping that steam will be admitted to. This is accomplished by the use of steam traps
and manual bypass valves to ensure positive drainage.

36. Discuss an alkaline boil out on a watertube boiler and reasons why.
An alkaline boil out is used to remove oil and grease type contaminants present in the
boiler after its erection or if the boiler gets contaminated during operation.
Discuss an inhibited acid cleaning on a watertube boiler and reasons why.
Inhibited acid cleaning is used to remove scale from inside the tubes. An inhibitor is
added to the acid to prevent or minimize the attack of the acid on the metal.
Discuss 5 reasons why chemical cleaning is preferred in a watertube boiler.
1) Less time and manpower required
2) Reaches hard to reach areas
3) Boiler can be designed with no special provisions for manual cleaning
4) Less costly than mechanical
5) Better quality cleaning is achieved
List 5 precautions when dealing with acid cleaning.
1) Assure correct acid for the job
2) Boiler isolated from steam header
3) Brass or bronze parts replaced with steel parts
4) The spent solvent is safely disposed of
5) Personnel handling the acid wear appropriate PPE
37. Sketch and describe wear rings on a centrifugal pump.

Wear rings are renewable pieces of material made of a softer substance than the
impeller and pump casing. Wear rings are placed between the impeller and the casing
to provide a sacrificial layer between them. This provides a minimal clearance
between the impeller and the casing to prevent excessive leakage from the discharge
into the suction. Wear rings are often made of bronze or cast iron since these materials
wear in a smooth manner.

38. Describe a wet layup and a dry layup of a boiler.

Wet layup of a boiler is used when the boiler is placed in a stand-by condition. The
boiler is either completely or partially filled with deaerated feedwater with oxygen
scavengers added to absorb any oxygen in the feedwater. A pressure slightly above
atmospheric is maintained during the storage period. If the boiler is only partially
filled with water, the remaining space above the water is filled with an inert gas and
pressurized to approximately 35 kPa.
This method is used when the boiler may be required for service on short notice. Wet
layup cannot be used if the boiler may be subjected to freezing temperatures.
Dry layup of a boiler is used when the boiler will be out of service for an extended
period of time or if the boiler will be exposed to freezing temperatures during the
standby.
Dry layup involves cleaning and thoroughly drying the boiler to prevent the onset of
corrosion. The vents on the drum, superheater, and economizer as well as other water
side vents are open to completely drain all the water from the boiler. The boiler is
then dried out by a small flame until no moisture is present at the drum vent. Moisture
absorbent material is then placed in the drum to absorb any moisture present in the
air. The boiler is then sealed up and pressurized with nitrogen gas to 35 kPa.
39. Sketch and describe a large watertube boiler (steam generator) with a
superheater, economizer and air heater.

40. Discuss the differences between:

Anthracite coal - Shiny black, contains little or no volatile gas which makes
it hard to light off. Considered a smokeless fuel suitable for firing in cities.
Over 90% carbon content. Over 30 MJ/kg HV. Hard to find.

Bituminous coal - Contains a fair percentage of volatile gases including

hydrogen and carbon mixtures. Easy to light off. Most popular power plant
fuel. HV of 20 - 30 MJ/kg.

Lignite coal - Brown in color, young, surface coal. High moisture and ash
content. Only used in plant is adjacent to coal field. HV of 16 MJ/kg or lower.

Where are ash and slag collected? (3 locations)

Ash and slag collects on the furnace walls, superheater section, reheater section,
economizer section and the air heater section. All these areas need to be sootblown to
remove the ash or slag.
Discuss the advantages of pulverized coal over normal coal for combustion
control.
Pulverized coal firing allows for a more intimate mixture of coal and air in the
furnace. This increases the efficiency and controllability of the heat release rate of the
fuel.
Why is bituminous coal easy to light off?
Due to its high volatile gas content.
Sketch and describe a bag house filter system.

A bag house system uses several filter bags, in parallel, and the principle is the same
as a vacuum cleaner. The fabric of the bags is large enough to allow the flue gas
molecules to pass through but small enough to catch the dust particles. Jets of air or a
rapper system is used to dislodge the dust particles which are carried away for
disposal.

41. Sketch and describe a hot lime water softener with a backwash filter system.

Raw water and chemicals enter the top of the softener through sprays, which
thoroughly mixes them together. Steam is introduced and deaerates the incoming
water. The chemical reactions occur almost instantaneously and the compounds form
sludge. After about a one-hour retention time the softened water is carried out through
and inverted weir to the outlet. As the sludge collects in the bottom some of it is
discharged to waste while some is recirculated to help reduce the amount of
chemicals needed for the process. The filters are arranged to be backwashed with
water from the softener and this water is returned to the softener, after backwashing.

42. What is welding flash?

Having the eyeballs burned from the ultra-violet rays emitted by electric arc welding
What causes welding flash?
The contact of the ultra-violet rays from the ERW process and unprotected eyes
What are the effects of welding flash and how is it treated?
Welding flash causes the eyeballs to blister and is very painful. If medical aid is not
immediately available then castor oil may be applied to the eyes to provide
lubrication for the eyelid over the eyeball. Teabags (used) applied to the eyes also
give some relief. Sunglasses should be worn for a few days after the flash occurs.
What safety precautions can be taken to prevent welding flash?
Wear suitable eye protection. Dark eyeglasses for the observers, and a proper welding
helmet for the welder.
What precautions should be taken when welding galvanized steel or cadmium
plated steel?
When welding galvanized or cadmium plated steel, toxic fumes are produced and
should be drawn away from the operator with adequate ventilation.

43. Sketch and describe the operation of a pop action safety valve.

The valve disc is held on its seat by the pressure of the spring. In the closed position
the pressure from the boiler acts on the area of the disk that is inside the seat area
only. When boiler pressure exceeds the preset spring pressure the disc is lifted off its
seat. As the disc lifts, the area the steam acts upon is increased thus increasing the
force on the disc. This increased force causes the valve to pop wide open. The valve
will remain open until boiler pressure has reduced sufficiently to allow the spring
pressure to return to the disc to its seat.
Explain how to adjust the blowdown
Blowdown is adjusted using the blowdown adjustment ring. The ring is adjusted up or
down to vary the amount of port opening, to allow steam to escape. If the ring is
adjusted upwards the blowdown will be longer as less steam will flow through port
and continue to act on the lip of the disc holding it open longer. If the ring is adjusted
downwards more steam is allowed to escape out the ports and less steam acts on the
lip of the disc and the valve closes sooner.
Why does the superheater safety valve pop before the boiler safety valve?

The superheater safety valve pops before and closes after the boiler safety valve in
order to keep a constant flow of steam through the superheater to prevent overheating.

44. List the advantages and disadvantages of economizers.

Advantages
1) Increased boiler efficiency due to the fact that heat is recovered from the flue
gases that would otherwise be lost up the stack.
2) Less thermal shock to the steam drum from the feedwater.
Disadvantages
1) Increased resistance to flue gas flow, bigger fan required
2) Increased resistance to feedwater flow, bigger pump required
3) Corrosion problems
4) Economizer heat surfaces must be clean for efficient operation
Compare an economizer vs. additional generating tubes for heat absorption.
Economizers are used instead of additional steam generating tubes because the
feedwater temperature is below the saturated steam temperature. Additional heat is
thus recovered from the flue gas leaving the boiler to the stack.
45. Define pressure explosion and furnace explosion
Furnace explosions occur when an accumulation of combustible gases ignite and
explode within the furnace (fireside), or gas passes of the boiler.
Pressure explosions occur when a pressure part of the boiler (waterside) fails due to
steam pressure, or structural weakening of the metal.
List 6 causes of pressure explosions
1) Overstressing of material due to too rapid heating up of the boiler at start-up.
2) Overheating due to low water level.
3) Overheating due to build up of scale, sludge, or oil on heating surfaces.
4) Overheating due to faulty water circulation in the boiler
5) Weakening of the material due to corrosion.
6) Boiler pressure above MAWP
List 5 causes of furnace explosions
1) Failure to purge the furnace adequately before start-up
2) Admission of fuel to main burner before pilot flame is established
3) The main flame gets blown out
4) Attempting to light one burner off another in operation
5) Accumulation of combustibles due to incomplete combustion

46. Describe the test for a low water fuel cutoff switch.
The low water fuel cut-off is tested by isolating the water supply to the boiler and
draining the water from the drum. The burner should shut down when the water level
is one inch above the bottom of the gauge glass.
Describe the care and maintenance that must be taken for a low water cut off?
One reason that the low water fuel cut-off may not work properly is the collection of
sediment in the float chamber. To prevent this, the chamber should be blown out
regularly. Another reason for malfunction is corrosion in the electrical contacts. This
can be prevented by a regular inspection and maintenance of the contacts. Another
reason for malfunction could be a binding of the linkage on the float due to corrosion.
Proper feedwater treatment should eliminate this problem.
47. Sketch and describe a 3 element feedwater control system and its advantage over
a 2 element system.

A three-element feed water control is superior to the two-element feedwater control

because it overcomes the effect of swell and shrinkage as well as responds to
feedwater upsets by measuring feedwater flow using an orifice plate and differential
transmitter.

48. Discuss the following steam traps:

Mechanical - made of either a ball float or a bucket float to open and close
the trap outlet valve, depending upon whether any condensate is present
within the trap body.

Thermodynamic - A disk type thermodynamic trap allows condensate to flow

by the force of the condensate lifting the disk off its seat. The condensate then
travels underneath it. When steam enters the trap, the steam expands and
travels at high velocity across the underside of the disk. Some of the steam
also passes up to the small space above the disk. The steam passing at high
velocity under the disk causes a pressure reduction in that area and the steam
above the disk, being at full pressure, forces the disk down, thus closing off
the outlet of the trap.

Thermostatic - utilize a bellows filled with a volatile fluid. When steam is in

the trap body, the volatile fluid boils and expands the bellows and closes off
the outlet valve. When cooler condensate enters the trap body, the volatile
fluid stops boiling and the bellows contract to open the outlet port and the
condensate exits.

49. Describe the procedure for replacing the packing on a pump.

1) Shut down, isolate and drain pump
2) Remove gland adjusting nuts and slide gland away from the stuffing box.
Then remove all the old packing using a packing puller. Make sure stuffing
box is thoroughly clean.
3) Check condition of the shaft, resurface if necessary
4) Determine the correct size of packing
5) Cut the required number of rings of packing, using an old shaft if possible as a
template.
6) Install the packing rings one at a time after putting a light coating of oil or
grease on the inner diameter of each ring. Tamp the rings into the stuffing box
one by one using a split wooden bushing or metal ring to push each ring into
place. Make sure the ring joints are staggered.
7) Put gland into place and compress the packing slightly by tightening the gland
nuts. Then slacken them off to just finger tight.
8) Prime and start the pump. Allow the packing to leak freely for a few minutes,
and then gradually tighten the gland until leakage is reduced to that necessary
for lubrication during normal operation.

1)

Discuss the procedures for the following nondestructive tests:

Radiographic - In this method x-rays or gamma rays are used to penetrate the
weld on one side and a sensitized photographic paper is placed on the other
side. Different amounts of radiation will come through depending on the
thickness and type of metal and show up on the film. Cracks, porosity, or light
slag inclusion in the weld will show up as darker areas on the film due to the
fact that more light will be let through in these areas.

Ultrasonic - In this method high frequency sound waves are directed into the
metal to be tested, and are reflected back and measured. Anomalies and
defects in the metal will reflect the sound waves in a different pattern. With
the use of a screen these waves can be seen as a wave signal and the defects
can be seen.

Dye-Penetrant - In this method dye is applied to the surface of the weld and
allowed to absorb into the flaw. The excess is wiped off and a black light is
beamed onto the affected area. The defect is revealed by means of the
fluorescent material absorbed in the flaw.

51. Explain why boilers require a good foundation

To ensure there is no movement due to settling which would result in extra stress in
the connecting pipe work, and cracking of any brickwork
What is the design that pulverized coal fired, high pressure, watertube boilers
use for support and why do they use it.
They are top supported and allowed to expand downwards
Why are tie bar and buck stay arrangements used on furnace casing?
To strengthen the casing in order to withstand the internal pressure on a forced draft
boiler.
Sketch and describe a tie bar and buck stay arrangement on a furnace corner

Tiebars or channels and buckstays surround the boiler horizontally. These buckstays
are steel beams that are bolted together on the corners in a manner that allows
expansion and contraction to take place.

52. Why is a degasifier used with a hydrogen zeolite softener?

The effluent from a hydrogen zeolite softener contains Carbonic acid. Carbonic acid
will quickly break down into CO2 and water. This CO2 must be removed from the
water to prevent corrosion. The degasifier does this job.
With the aid of a sketch, explain the operation of the degasifier.

The degasifier removes the CO2 by passing the water through a tower in which the
water flows down over trays and is scrubbed by upward flowing air, from a blower,
and the CO2 is released to the atmosphere. The treated water falls into the clearwell
below the tower for storage.

53. Sketch and describe any remote level indicator

Igema remote water-level indicator

The steam condenser maintains a constant head of water acting at the top of the
indicator glass that contains a colored indicating liquid. The right column of water or
varying head is exposed to the liquid level in the drum and the right side of the Utube containing the indicating liquid. When the level in the boiler steam drum is at
minimum, the pressure differential between the two heads will be the greatest. The
indicating liquid will be forced downward to the bottom of the indicator glass. As the
level rises in the drum, the indicating liquid will also rise in the glass, giving a
colored indication of the level to the operators on the operating floor.
What is the purpose of the expansion pipe and the condenser chamber?
The expansion or equalizing pipe prevents the indicator from being subjected to
boiler pressure on one side only. The condenser chamber is used to maintain a fixed
head of water on the steam-space side. Surplus condensate returns to the level of
water in the boiler.

55. Sketch and describe a multi-element combustion control system on a high

pressure boiler

An increase in firing rate demand is sent by the high selector to be the set point for
the air flow and the low selector sends the airflow process variable to be the set point
for the fuel flow. This ensures that the airflow leads and the fuel follows to prevent a
rich condition.
A decrease in firing rate demand is sent by the low selector to be the set point for the
fuel flow and the high selector sends the fuel flow process variable to be the set point
for the air flow. This ensures that the gas decreases first, then the air to prevent a rich
condition.
The O2 controller ensures that the percentage of excess air will be reduced at
increased steam demand, and increased, at a decrease in steam demand.

56. What is the purpose of an air heater on a large steam generator?

To recover heat from the flue gas and use it to preheat the combustion air to the
burners
Describe 2 types of air heaters
A recuperative air heater has heat transferred directly from the flue gases on one side
of the heating surface to the inlet air on the other side of the heating surface.
A regenerative air heater absorbs heat from the flue gasses onto a metal, or other solid
surface, and then this surface is repositioned to allow the heat to be transferred to the
combustion air.
Explain where and why corrosion occurs in an air heater
Boiler flue gases contain sulphur compounds. When the flue gases are cooled to a
certain point (dew point), sulphuric acid will condense and form on the air heater
surfaces and cause corrosion. Areas most vulnerable are at the cold end of the unit,
the flue gas exit.
What can be done to prevent or minimize corrosion in an air heater?
Keep the flue gas temperatures above the dew point. This can be done by recirculating the air from the heater outlet to the heater inlet, or bypassing a portion of
the inlet air around the heater and mixing it afterward with the heated air.
57. List 5 characteristics of a plant fuel and explain how they effect plant operation.
1) Specific Gravity - the higher the specific gravity, the lower the hydrogen
content and the harder it is to ignite the fuel
2) Heating Value - this is needed to calculate the boiler efficiency
3) Flash Point - determines the safe temperature at which the fuel can be stored
4) Congealing or Pour Point - determines the temperature at which the oil will
refuse to flow
5) Viscosity - measure of resistance to flow, the higher the reading the more
trouble it is to burn. (heaters, etc)
54. What is post weld heat treatment (PWHT) and how is it performed.
PWHT is the heating of the welded material subsequent to welding. The metal is
uniformly heated to a temperature sufficient to relieve most of the stresses created by
the welding process. The parts are then cooled at a constant rate
Why is PWHT used?
To relieve the stresses created by the welding process on the weld metal and the base
metal. This is done to help prevent the weld from cracking when it cools.

58. Explain the startup procedure of a 15 000 kPa steam atomizing boiler using
Bunker C oil.
1) Ensure oil tank temperature is 30oC
2) Perform a proper purge of the furnace (5mins)
3) Check all burner connections
4) Check water level and position of all boiler valves, open superheater drains
5) Open oil circulating valve at burner and start fuel oil pump
6) Put heating steam on fuel oil heater, raise temp to 90 - 94oC
7) Close oil circulating valve
8) Open back draft damper
9) Drain steam line to burners
10) Open air register slightly
11) Open steam valves and blow steam through the burner until steam is dry
12) Ensure boiler clean out valve is shut and throttle steam to burner
13) Place a lighted torch through the observation door near the burner tip
14) Carefully open the oil valve to allow enough oil to pass to ignite the burner, at
the same time increase the air register opening and increase the atomizing
steam
15) When the burner is properly ignited, withdraw the torch.
What are 5 interlocks which will cause the fuel solenoid valve to trip?
1) Fan failure
2) Low oil supply pressure
3) Low combustion air pressure
4) Low water level
5) Flame failure
6) MAWP exceeded

59. Sketch a reducing valve station of a boiler producing 2000 kPa down to 1000 kPa
for process usage and down to 103 kPa for heating.

Sketch and describe a spring pressure reducing valve

60. Explain the purpose of the following water tests:

Hardness - To determine the amount of calcium and magnesium salts in the

water. Water should be at 0 ppm

Phosphate - To ensure there is a residual amount of phosphate circulating in

the boiler. This residual phosphate ensures that any calcium and/or magnesium
hardness can be reacted with.

Sulphite - To ensure boiler water contains an excess of 20 ppm sulphite,

which will indicate that no dissolved oxygen exits

Nitrate - Chloride test. Used to determine the % blowdown required, and if

seawater is leaking into the feedwater system where applicable.

Conductivity - To measure the total dissolved solids in the boiler water. This
is important since too much dissolved solids in the water can lead to carryover
from the boiler.

61. Sketch and describe the operation of a pressure gage.

The bourdon pressure gauge contains an oval tube in the form of a C, having an arc
of about 270o. One end of the tube is sealed and the other is connected to the steam
pressure. As the pressure increases it forces the oval tube into a more circular shape.
This causes the free end of the tube to move linearly. The free end of the tube is
attached to a pointer and indicator assembly to record the pressure applied.
What is the purpose of the siphon tube?
The purpose of the steam gauge siphon is to prevent steam from entering the gauge
and damaging it. The siphon is basically a loop in the pipe between the boiler and the
gauge. This allows the steam to condense in the upper part of the pipe, and prevent
steam from entering the gauge.
Where are the inspectors test gage connected?
The connection for the Inspectors test gage is a tee fitting with one branch plugged,
and is located between the siphon tube and the gage connection.
What is the procedure to test a gage?
One method is to use the test connection while the boiler is in operation and compare
the boiler gage to the inspectors test gage. This only compares the current pressure.
A more accurate method involves removing the gage from the boiler and using a
deadweight tester to test the gage throughout its entire range.

62. Sketch and describe a direct positioning combustion control system

A direct pressure combustion control system senses changes in boiler load and
regulates the fuel/air supply to the burners to match load. One controller is used for
both fuel and air, so the fuel-air ratio trim has to be manually adjusted for different
firing rates.
Explain why this system cannot be used on large high pressure boilers.
The control of the fuel-air ratio is not precise enough for large pressure boilers as a
slight increase in boiler efficiency can save a lot of money.

63. Sketch and describe an inverted bucket steam trap.

The bucket initially hangs down and holds the discharge valve open. Condensate enters
the trap and flows under the bottom edge of the bucket to fill the trap body. Then the
condensate will flow out through the open discharge valve at the outlet. Any steam that
enters the trap will collect at the top of the inverted bucket giving it buoyancy and
causing it to rise, thus closing the discharge valve. Air and CO2 gas will also collect at the
top of the inverted bucket and will pass through the vent at the top of the bucket to the
upper part of the trap body.
64. Explain the purpose and advantage of:

Closed feedwater heater - To increase plant efficiency by preheating the

boiler feedwater. Being a closed design allows them to be placed anywhere in
the plant cycle including the discharge of the boiler feed pumps. Higher
temperatures are obtained over open feedwater heaters.

Evaporator - To remove the dissolved solids from the feedwater. Uses

exhaust heat from the turbine to distill the water instead of using chemicals
and demineralizers.

Deaerator - To remove O2 and CO2 from the water and serve as a feedwater
heater. Removes the gases which otherwise would need to be removed by
chemical means.

Sketch and describe a deaerator.

In a combination spray and tray type deaerator, the water is first sprayed into the
upper heating section, and then allowed to trickle down over a series of steam swept
trays. This way the released gases and remaining steam traveling to the vent will pass
through the incoming water spray, condensing most of the steam. This section is
called the internal vent condenser.

65. What are 3 advantages and 3 disadvantages of continuous and intermittent

blowdown?
Advantages
1) Removal of dissolved solids from the steam drum (CBD)
2) Removal of suspended solids from the mud drum (IBD)
3) Provides drainage of the waterside of the boiler (IBD)
Disadvantages
1) Heat loss causing a decrease in overall steam system efficiency
2) Loss of treated water, thus requiring more make-up water
3) Required piping and blowdown tank, extra costs
Sketch a single line drawing of an intermittent blowdown

What is the difference between a quick opening and slow opening valve?
A quick opening valve is one which is opened or closed by moving a lever or wrench
through a small arc.
A slow opening valve is one which requires at least 5 360o turns of the operating
mechanism to change from full closed to full open and vice-versa.
66. A steam driven feedwater pump starts and stops immediately during startup,
then the relief valve opens. What is the cause and how are you going to correct
it?
The cause is that the exhaust or LP steam valve is closed. The relief valve opens as
the casing builds pressure and has no place to go, this is also why the rotor stops
turning. To correct this first close the intake valve and then open the exhaust valve
wide open (assuming the casing and piping are drained of condensate and warmed
up). Now open the intake again and the pump should start and keep running.
67. You are operating by yourself when the diaphragm on your feedwater control
valve bursts. Identify the procedures for properly and safely dealing with this
situation.
First thing would be to isolate the FCV and open the bypass valve to maintain water
flow to the boiler. Put feedwater control to hand. Regulate feedwater flow manually
to match steam demand to ensure a proper drum level. If there was a spare FCV I
would swap it out (if I was allowed), if not I would keep a close eye on drum level
until maintenance arrived.

68. Sketch and describe submerged arc welding.

An arc welding process where the welding occurs beneath a protective layer of
granular and molten mineral material. This is normally an automatic process that
produces seams which are neat and uniform in appearance