Question & Answers on Steam Turbines

What is a stage in a steam turbine?

Answer: In an impulse turbine, the stage is a set of moving blades behind the
nozzle. In a reaction turbine, each row of blades is called a "stage." A single
Curtis stage may consist of two or more rows of moving blade.

What is a diaphragm?

Answer: Partitions between pressure stages in a turbine's casing are called

diaphragms. They hold the vane-shaped nozzles and seals between the stages.
Usually labyrinth-type seals are used. One-half of the diaphragm is fitted into the
top of the casing, the other half into the bottom.

What is a radial-flow turbine?

Answer: In a radial-flow turbine, steam flows outward from the shaft to the
casing. The unit is usually a reaction unit, having both fixed and moving blades.
They are used for special jobs and are more common to European
manufacturers, such as Sta-Laval (now ABB).

What are four types of turbine seals?

Answers:
1.Carbon rings fitted in segments around the shaft and held together by garter or
retainer springs.
2.Labyrinth mated with shaft serrations or shaft seal strips.
3.Water seals where a shaft runner acts as a pump to create a ring of water
around the shaft. Use only treated water to avoid shaft pitting.
4.Stuffing box using woven or soft packing rings that are compressed with a
gland to prevent leakage along the shaft.

In which turbine is tip leakage a problem?

Answer: Tip leakage is a problem in reaction turbines. Here, each vane forms a
nozzle; steam must flow through the moving nozzle to the fixed nozzle. Steam
escaping across the tips of the blades represents a loss of work. Therefore, tip
seals are used prevent this.

What are two types of clearance in a turbine?

Answer:
1.Radial - clearance at the tips of the rotor and casing.
2.Axial - the fore-and-aft clearance, at the sides of the rotor and the casing.

What are four types of thrust hearings?

Answer:
1.Babbitt-faced collar bearings.
2.Tilting pivotal pads.
3.Tapered land bearings.
4.Rolling-contact (roller or ball) bearings.

What is the function of a thrust bearing?

Answer: Thrust bearings keep the rotor in its correct axial position.

What is a balance piston?

Answer: Reaction turbines have axial thrust because pressure on the entering
side is greater than pressure on the leaving side of each stage. To counteract this
force, steam is admitted to a dummy (balance) piston chamber at the low-
pressure end of the rotor. Some designers also use a balance piston on impulse
turbines that have a high thrust. Instead of piston, seal strips are also used to
duplicate a piston's counter force

Why should a steam or moisture separator be installed in the steam line next to a
steam turbine?

Answer: All multistage turbines, low-pressure turbines, and turbines operating at

high pressure with saturated steam should have a moisture separator in order to
prevent rapid blade wear from water erosion.

What are some conditions that may prevent a turbine from developing full power?

Answers:
1.The machine is overloaded.
2.The initial steam pressure and temperature are not up to design conditions.
3.The exhaust pressure is too high.
4.The governor is set too low.
5.The steam strainer is clogged.
6.Turbine nozzles are clogged with deposits.
7.Internal wear on nozzles and blades.

Why is it necessary to open casing drains and drains on the steam line going to
the turbine when a turbine is to be started?

Answers:
To avoid slugging nozzles and blades inside the turbine with condensate on start-
up; this can break these components from impact. The blades were designed to
handle steam, not water.

What is steam rate as applied to turbo-generators?

Answer: The steam rate is the pounds of steam that must be supplied per
kilowatt-hour of generator output at the steam turbine inlet.

What are the two basic types of steam turbines?

Answers:
1.Impulse type.
2.Reaction type.

What is the operating principle of an impulse turbine?

Answer: The basic idea of an impulse turbine is that a jet of steam from a fixed
nozzle pushes against the rotor blades and impels them forward. The velocity of
the steam is about twice as fast as the velocity of the blades. Only turbines
utilizing fixed nozzles are classified as impulse turbines.

What is the operating principle of a reaction turbine?

Answer: A reaction turbine utilizes a jet of steam that flows from a nozzle on the
rotor. Actually, the steam is directed into the moving blades by fixed blades
designed to expand the steam. The result is a small increase in velocity over that
of the moving blades. These blades form a wall of moving nozzles that further
expand the steam. The steam flow is partially reversed by the moving blades,
producing a reaction on the blades. Since the pressure drop is small across each
row of nozzles (blades), the speed is comparatively low. Therefore, more rows of
moving blades are needed than in an impulse turbine.

What are topping and superposed turbines?

Answer: Topping and superposed turbines arc high-pressure, non-condensing

units that can be added to an older, moderate-pressure plant. Topping turbines
receive high-pressure steam from new high-pressure boilers. The exhaust steam
of the new turbine has the same pressure as the old boilers and is used to supply
the old turbines.

What is an extraction turbine?

Answer: In an extraction turbine, steam is withdrawn from one or more stages, at
one or more pressures, for heating, plant process, or feedwater heater needs.
They are often called "bleeder turbines."

What is a combination thrust and radial bearing?

Answer: This unit has the ends of the Babbitt bearing extended radially over the
end of the shell. Collars on the rotor face these thrust pads, and the journal is
supported in the bearing between the thrust collars.

What is a tapered-land thrust bearing?

Answer: The babbitt face of a tapered-land thrust bearing has a series of fixed
pads divided by radial slots. The leading edge of each sector is tapered, allowing
an oil wedge to build up and carry the thrust between the collar and pad.

1. List three scale forming compounds and the type of scale they form (hard, soft,
and insoluble).

2. True or False? A synchroscope compares the generators waveform to the

grids waveform by measuring the phase angle between the two.

3. What are some causes of pitting and corrosion?

4. How do you determine the set-point of a super heaters safety valve?

5. During rounds of a large generating station you notice the thrust bearing
temperature has increased from its normal temperature of 130F to 145F. All the
other parts of the turbine system are normal. is there a problem, and what do you
do?

6. How do you adjust the radial clearances on a turbine?

7. Draw a picture of a cross compound turbine and indicate all the staging.

8. A flue gas analysis showed 15%co2 and 5% o2, by volume, whats the excess
air?

9. What do the symbols in ohms law represent? E=IR?

10. What pressure is a blank cover plate good to (in place of a safety valve
during a hydro)? The dimensions and strength of the plate was given. The
formula to solve was given, T=d/cp/s.

11. What is an accumulation test? and when should one never be performed?
12. Explain a zeolite water softener process?

13. What is the maximum amount of carbon that can be in boiler pressure part
metal?

14. When steam passes through a P.R.V. what happens to the temperature,
pressure, entropy, enthalpy, and superheat?

15. What flue gasses are measured to control pollution instead of for combustion
efficiency?

16. Name the parts that make up a large surface condenser? (Theres 7 items)

17. Name several causes of turbine vibration.

18. What is a water seal gland and how does it work?

19. Whats the specific heat of steam, oil and air?

20. How do you know when a shell and tube feed water heater is leaking in the
tubes?

1. Who can adjust safety valves settings and how can you tell if it alright to put
in service?

2. What is a single butt weld and a double butt weld?

3. How do you determine water rate?

4. Name three ways to find minimum safety valve capacity?

5. How often do air tanks need to inspected?

6. Which clearance is more vital in a reaction turbine axial or radial and why?

7. What is a yield point in regarding metal?

8. Why must coal be sampled and tested in a power plant?

9. Using steam flow how do you determine the horsepower of turbine? What
is the water rate?

10. What are 5 reasons for a gradual vacuum loss in a condenser?

11. What are the reasons for superheater failure? Give measure to prevent
these failures.
12. A steel bean 33 long and the temperature is raised 50 degrees C, how long
will the beam be after expansion? Assume expansion is 10 x 10 - 6.

13. During turbine warm up should the vacuum be maintained high or low and
why?

14. What is the furnace heat release 15 x 10 x 46, fuel rate 90gpm and 146,000
Btus/gal?

15. What is the theoretical discharge pressure of a 12 x 6 x 8 pump operating

at 125 psi?

16. A 200 MAWP boiler has 3 safety valves, what is the range of these valves?

17. What is excess air?

18. What is an exciter and how does it operate?

19. What does an increase in excess air do to a boiler with an integral

superheater? Firing rate is unchanged, describe the effect on superheater
temperature, boiler pressure and stack temperature.

1. A boiler rated for 150,000 Lb of steam per hour only delivers 135,000 Lb of
steam give four possible causes.

2. Define net positive suction head what is the difference between required
NPSH and available NPSH.

3. When would you reject a welders test coupon.

4. What is a non-destructive test? give some examples What do the NDT look
for? (this was a welding question)

5. What are these ASME stamps? S, M, E, A

6. What are these elements? N, S, O, H

7. What would these chemicals be used for in a boiler or it's appurtenances?

sodium sulfite, sodium hydroxide, sodium chloride zeolite.

8. What is the efficiency of this boiler 10,000 Lb steam 150 psi quality 100%
feedwater temp 212 700 gallons of oil burnt in an hour 18,000 btu/gallon enthalpy
of steam 1,151.3

9. Define factor of evaporation and give the formula.

10. What is water hammer give cause result and remedy?

11. What are the requirements on a blow down tank piping?

12. What are the blow down requirements for a 150 MAWP boiler for both piping
and valves?

13. Define BLOW DOWN as applies to safety valves Who can adjust blow down
on a safety valve What is the minimum and maximum range of blowback on a
natural circulation boiler. What is the plus or minus on the popping pressure of a
safety valve on a 250 MAWP boiler?

14. What information is on the state log book?

15. Dimensions of a furnace given and gallons of oil per minute burned and Btu
content give the furnace heat release.

16. What is a conductivity test?

17. Describe the construction and operation of Kingsbury thrust bearing.

18. What type of turbine develops more end thrust impulse or reaction and why?

19. What does an increase in excess air do to a boiler with an integral

superheater firing rate is unchanged describe the effect on superheater
temperature, boiler pressure and stack temperature.

20. What is specific gravity?

12. What are the blow down requirements for a 150 MAWP boiler for both piping
and valves?

13. Define BLOW DOWN as applies to safety valves Who can adjust blow down
on a safety valve What is the minimum and maximum range of blowback on a
natural circulation boiler. What is the plus or minus on the popping pressure of a
safety valve on a 250 MAWP boiler?

14. What information is on the state log book?

15. Dimensions of a furnace given and gallons of oil per minute burned and Btu
content give the furnace heat release.

16. What is a conductivity test?

17. Describe the construction and operation of Kingsbury thrust bearing.

18. What type of turbine develops more end thrust impulse or reaction and why?

19. What does an increase in excess air do to a boiler with an integral

superheater firing rate is unchanged describe the effect on superheater
temperature, boiler pressure and stack temperature.

20. What is specific gravity?

1. Define Factor of Evaporation. Give the formula.

2. What are 3 ways to find the relieving capacity of a safety valve

3. What do these chemicals do for water?

a. Sodium Sulfite

b. Sodium Hydroxide

c. Sodium Chloride

4. What does bleed steam do for turbine efficiency when bleeds are used as
feed water heaters?

5. Oil weighs 6.91 lb/gal with 39 API specific gravity. Whats lb/ft3 ? How
many barrels are there in 100 tons? (Note 1 gal of water weighs 8.33 lb)

6. A question that asks about throttle valves and nozzles . I think it was
looking for throttling losses and why is it better to control steam flow with nozzles.

7. Air ejector condensers discharge directly into

a. Main condenser

b. Aux condenser

c. Condensate and feed water system

8. A boiler produces 148,000 lb/hr of steam per lb of coal consumed. The

feed water temp is 212F. BTU value of the coal is 14,645 BTU/lb. What is the
boiler efficiency?

9. What are 4 causes for a turbine to appear dynamically unbalanced when it

actually is?

10. Is pressure or temperature more Injurious to a boiler?

11. When can you close the generator breaker on a turbine on turning gear?
Why?

12. List 4 trips on a modern gas turbine.

13. Describe a wet boiler lay up?

14. What is the main purpose of a hole bored in the center of a turbine shaft?

15. A question that asks how you check a weld after post heat treatment?

16. Calculate the heating value for 85% carbon, 5% hydrogen, 5% oxygen, and
1% sulfur.

17. If condenser tubes are rolled at each end how does expansion occur?

a. Bellows tube sheet

b. Casing expansion joint

c. Condenser sliding feet

d.

18. Impulse or reaction turbine? Which one weighs less and is smaller per
mechanical horsepower produced?

19. What is the principal operation of an air ejector?

1. What is a steam boiler under ASME code as far as pressure and temp?

2. What is combustion? In detail.

3. What happens to latent heat when process is increased or decreased?

4. Who can be in charge of a 2nd class plant?

5. A boiler rated for 150,000 lbs/hr and is putting out 130,000 lbs/hr. Give 4
reasons why its not putting out its max.

6. Name four trips on a turbine.

7. What is end point on a circulation process?

8. What is galvanic corrosion and how is it prevented?

9. What is a reinforcement weld?

10. What is rotor long and rotor short?

11. Calculate the combustion air require for 10% carbon, 5% Hydrogen, 5%
Oxygen and 3% Sulfur.

12. What is an adiabatic process and where does it take place in a power plant?

13. A boiler generates 10,000 lbs of steam per hour and has a factor of
evaporation of 1.24, what is the developed boiler horsepower?

14. What is blow down or blowback on a safety valve?

What is the setting of percentage of blowback?

15. How much can a 250 lb safety valve be adjusted above or below set
pressure? Who can adjust the safety valve?

16. Has an authorized inspector any right to disagree with the manufacturers
records and call for re qualification of a welder or to have physical test made
again?

17. What do these chemicals do for water:

Sodium hydroxide?

Sodium sulfite?

Sodium chloride?

1. According to M.G.L. Chapter 146, Section 34, how often should air tanks be
inspected? What pressure should they be inspected?

2. What is a convergent-divergent nozzle? Why is it better than a convergent

nozzle?

3. What is sub or under cooling?

4. What is a dummy micrometer used for?

5. Name 4 ways to tell if a bearing has gone high temperature.

6. What is the difference between bleed and extraction steam?

7. What is excess air?

8. What is a root pass in relation to a weld?

9. How does a bomb calorimeter work?

10. On some turbines, why are there more than one steam inlet lines?

11. What is specific gravity?

12. A question of a fuels but per/lb burning 82% efficient, using an amount of
fuel in lb/hr. What was the btu loss?

13. What boilers come under the ASME Power Boilers Section 1.

14. How does a hydraulic governor work?

15. When do air conditioning units require inspection?

16. If the condenser tubes are rolled at each end, what takes the expansion on
the condenser. (This was a multiple choice question)

17. You need a turbine, 40 pounds and a large volume of steam and exhaust to
a condenser. What type of turbine are you going to order.

18. Another multiple choice question, I forgot what it was.

19. How do you determine who can be in charge of a certain plant?

20. Who can be in charge of a second class plant?

1. Determine developed boiler horsepower given steam flow and factor of

evaporation.

2. Required oil pressure at bearing is 8 psig. Oil tank is 20 feet above. Is oil
pressure enough. S.G is .75.

3. Purpose of converging-diverging nozzle and benefit over converging nozzle.

4. Purpose and operation of gland exhauster condenser.

5. Flat gage glass vs. tubular gage glass.

6. Furnace heat release calculation given dimensions of furnace in feet, oil

flow rate and heating value.
7. Cause of laminations/blisters and what repairs can be made.

8. Btus in a BHP; Btus in a mechanical HP

9. Boiler efficiency calculation given10.9# water evaporated per pound of coal,

FW=212, HV=14,645Btu/#

10. 2 ways to repair corrosion around a manhole.

11. What is combustion

12. Difference between a SV and a SRV (ASME code).

13. Air ejector principle of operation.

14. Necessary safety appliances for a power boiler.

15. Type of turbine with greatest end thrust and why

16. 2" pipe supplying steam. Pipe is increased to 6". How much more steam?

17. 1000kw generator. How many horsepower?

18. Bomb calorimeter. What is it and how is it used?

19. Blow down pipe and valve requirements for 150 psig boiler.

20. Napiers law: W=51.5 AP. Given steam flow (W), and pressure is 400psia
what is the required safety inlet diameter.

1. why is a steam turbine is less efficient than a boiler.

2. Define Specific Gravity, Power, Stress and Strain

3. What is the Specific heat of Oil, H2O, Steam, and Air

4. A drawing of a GT Burner that illustrates parts, describe what each

component does and what maintenance problems exist with each component

5. What are the three main areas of concerns when it comes to stress when
determining the working pressure of a fire tube boiler

6. What is Radial flow in a Steam Turbine

7. 72 tubes 3 OD 66D 18 ft in length, what is the heating surface of a fire

tube boiler neglecting the tube sheet, consider the heads to be .
8. List/explain the qualities of oil for a turbine?

9. How would you detect a leak in a closed loop feed water heater?\

10. Where does steam turbine blade erosion occur, what causes it?

11. How is power made in a gas turbine?

12. How are tubes attached in a condenser

13. What causes vibration on a steam turbine?

14. What qualifications must you have to sit for this license?

15. You are purchasing a 10,000,000 BTU boiler for use in MA, according to
CMR what environmental controls will be required?

16. How are flame monitors positioned in reference to igniters and why?

17. What is latent heat, sensible heat?

18. What stops a turbine from over-speeding after a trip?

19. After repairing an inverted bucket trap, what is the first thing you do before
placing it back into service?

1) Define/what is the difference between a safety valve, relief valve, and a

safety-relief valve.

2) Describe three methods of sealing a turbine casing and shaft

3) What is static and dynamic balancing?

4) Name LO tests that can be performed without a chemical analysis.

5) Name three requirements of an efficient shaft bearing.

6) Why are water walls used in boilers? In detail.

7) Why does turbine efficiency increase when a condenser is used?

8) You need to order a safety valve for a new boiler what do you need to
know?

9) How does the efficiency increase by heating feedwater?

10) Name three ways the shell/casing is allowed to expand/contract on the HP
end of a ST.

11) What prevents a turbine from overspending from the steam in the reheater
after a trip?

12) What is the max carbon permitted in boiler steel?

13) What does dissolved oxygen do in a boiler, how do you prevent it?

14) How do you wash a turbine?

15) What is axial clearance? How do you adjust a turbine axially?

16) What causes corrosion and pitting? How do you prevent it?

17) How does a GT produce its power?

18) Explain how a Selective Catalytic Reduction system on a combined cycle

unit works.

19) On a boiler, the manufacturers data plate states that it produces 345 #/hr,
the owner requests that a second data plate be installed which states the HP is
8.5, and that it has a BTU input of 356000 BTUs. Which one is correct?

20) Drawing of a GT with a regenerator, state why a regenerator would be used.

Why is a steam turbine less efficient than a boiler?

2. Define Specific Gravity, Power, Stress and Strain
3. What is the Specific heat of Oil, H2O, Steam, and Air?
4. A drawing of a GT Burner that illustrates parts, describe what each component
does and what maintenance problems exist with each component.
5. What are the three main areas of concerns when it comes to stress when
determining the working pressure of a fire tube boiler?
6. What is Radial flow in a Steam Turbine?
7. 72 tubes 3 OD 66D 18 ft in length, what is the heating surface of a fire tube
boiler neglecting the tube sheet, consider the heads to be .
8. List/explain the qualities of oil for a turbine?
How would you detect a leak in a closed loop feedwater heater?
11. Where does steam turbine blade erosion occur, what causes it?
12. How is power made in a gas turbine?
13. How are tubes attached in a condenser
14. What causes vibration on a steam turbine?
15. What qualifications must you have to sit for this license?
16. You are purchasing a 10,000,000 btu boiler for use in MA, according to CMR
what environmental controls will be required?
17. How are flame monitors positioned in reference to igniters and why?
18. What is latent heat, sensible heat?
19. What stops a turbine from over-speeding after a trip?
20. After repairing an inverted bucket trap, what is the first thing you do before
placing it back into service?

WHAT IS THE PURPOSE OF A SYNCHROSCOPE?

DESCRIBE A WET LAY-UP BOILER PROCEDURE?

WHAT ARE RESIN BEADS MADE OF?

WHAT IS A SENTINEL VALVE?

DURING NORMAL OPERATION A CONDENSER MAINTAINS VACUUM WITH

ONLY ONE SET OF AIR EJECTORS, HOW IS THIS POSSIBLE?

WHAT IS A TOPPING TURBINE?

A BOILER PRODUCES 10.9 POUNDS OF STEAM PER POUND OF COAL

CONSUMED, THE FEEDWATER TEMPURATURE IS 212 DEGREES F. THE
BTU VALUE OF THE COAL IS 14,645 BTU/LB. WHAT IS THE BOILER
EFFICIENCY?

DEFINE YIELD POINT AS IT APPLIES TO METAL?

A BOILER PRODUCES 148,000 POUNDS OF STEAM PER HOUR, THE BLOW

DOWN RATE IS 5%, WHAT IS THE DAILY BLOW DOWN TOTAL IN POUNDS
AND HOW MANY BTUS ARE LOST PER DAY IF THE FEED WATER
TEMPERATURE IS 400 DEGREES F. ?

DEFINE REINFORCEMENT AS IT APPLIES TO A WELD?

WHAT IS A WET BOTTOM FURNACE AND A DRY BOTTOM FURNACE?

DESCRIBE OIL OPERATED OIL RELAY GOVERNOR IN DETAIL?

WHAT IS AN EXCITER AND WHAT IS ITS FUNCTION?

HOW MANY SAFETIES WOULD A 510 KW INPUT BOILER REQUIRE AND

WHAT IS THE BLOW DOWN CAPACITY?

NAME 6 LOSSES IN A TURBINE?

DEFINE SPECIFIC GRAVITY?

WHAT ARE THE TWO PRIMARY

CONSTITUENTS OF THE ATMOSPHERE IN PERCENTAGE BY VOLUME?
WHAT DOES THE PH IN A PH TEST INDICATE?

WHAT IS THE HORSEPOWER OF A 1000 KW GENERATOR?

YOU NEED A CONDENSING TURBINE AND YOUR PLANT PRODUCES

STEAM AT 40 PSI IN VERY HIGH VOLUMES. WHAT TYPE OF TURBINE
WOULD YOU BUY AND WHY?

1) What is ultimate analysis? Proximate analysis? Explain in detail.

2) What is a shroud?

3) Blade speed of turbine is 400 RPM and blades are 48. Steam speed is
11500 ft/min. What is relation between blade speed and steam speed?

4) What is rotor long? Rotor short?

5) Explain procedure for blow down of a boiler with one quick opening valve
and one slow opening valve. Explain the difference between blowdown and blow
off systems.

6) What is a watt?

7) Show three ways to find relieving capacity of a safety valve.

8) How are radial clearances measured in a turbine?

9) Why does an auxiliary pump stay running when turbine is secured?

10) How do you remove a poor weld that needs to be done over?

11) How do superheater tube failures occur? How do you prevent these
problems?

12) Name the combustible components in coal?

13) A steel beam is 33 ft. long and the temperature is raised 50 degrees C. How
long will the beam be after expansion? Assume expansion coefficient is 10 X 10
to the -6th power.

14) Does bleeding steam from a turbine for pre heating affect turbine efficiency?
15) Which part of the boiler receives the most pressure?

16) What information is found in the state operators log book?

17) What is the purpose of a syncroscope ?

18) Pump 1 can empty a tank in 6 hours. Pump 2 can empty same tank in 5
hours. How long will it take to empty the same tank using both pumps at the
same time?

19) Is pressure or temperature more injurious to a boiler?

20) Describe principle operation of an air ejector.

1. Why does the auxiliary oil pump run after the turbine has been shut
down and secured.

2. What is water hammer and how is it prevented.

3. Name the two types of air Preheaters.

4. What is critical speed.

5. Calculation on furnace heat release.

6. What is the difference between convergent and

convergent/divergent nozzles

7. What is a gland steam exhaust condenser.

8. When warming up a turbine, should your vacuum be high or low?

Explain

9. Describe an oil operated oil relay governor.

10. Why are flexible couplings used? Explain types.

11. How is turbine connected to a feed pump, and explain how to align.

12. Calculation on firing rate.

13. Steam velocity compared to blade velocity calculation.

14. What can you do with this license.

 15. According to the Code, how much steam should safety valves
relieve?

16. List 4 safety devices on a gas turbine.

17. Explain an exciter.

1) Why are flexible couplings used on main turbines, describe a gear or

dental type?

2) What is the main purpose of a hole bored in the center of a turbine shaft?

3) What is a spindle or dummy micrometer used for?

4) How much heat is required to melt one pound of ice at 32 * F

5) A boiler efficiency calculation.

6) A combustion efficiency calculation.

7) ws=51.5ap ws=28000 lb/hr p=400 solve for A.

8) Who is authorized to adjust safety valves and how can you tell if a safety
valve is alright to install?

9) PH reading is the concentration of ----- ?

10) You are on watch at your plant, turbine is off line and on the turning gear,
when can you close the generator breaker and why?

11) List four safety devises on a gas turbine?

12) List the operation and maintenance procedures to avoid compressor

fouling on a gas turbine?

13) What does the commonwealth require of a person performing the duties
of the engineer in charge of a second class plant, what license is required?

14) List four things that would cause a turbine to appear unbalanced when it
actually was balanced?

15) What is a blow down tank and what the piping requirements?

16) How are throttling losss minimized in a steam turbine?

17) Why do we measure electric conductivity in boiler water?

18) When is a radio graph and stress relieving required on a welded repair?

19) What precautions should be taken while welding or inspecting a weld?

20) What happens to the latent heat as the pressure goes up?

1. Name three ways that expansion and contraction of rotor and casing are
handled at the H.P. End of the turbine?

2. How is over speeding of a turbine that has a reheater prevented after the
turbine has tripped?

3. A steam heating system is changed from a 2 diameter header to a 6

diameter header. How much more steam can the header handle?

4. On a reaction turbine, which clearances are more crucial axial or radial?

5. What is the first step to setting up a water treatment program?

6. What is the effect of dissolved oxygen on boiler feedwater and how is it

removed?

7. What are; Sodium Sulfite? Sodium Hydroxide? And Sodium Chloride?

8. True or false, Definition of a synchroscope? (Discusses phase angle and

voltage).

9. In a surface condenser, how can you tell if vacuum loss is due to air
infiltration or a dirty condenser?

10. Why does having a condenser improve turbine efficiency?

11. Explain the operation of an air ejector?

12. In a combined cycle gas turbine plant, what major maintenance repair is
done to fix compressor fouling?

13. In a combined cycle gas turbine plant, what major operation procedures can
be done to prevent compressor fouling?

14. A new boiler in your plant has a tag on it that states it has 65 sq. ft. heating
surface and operates at 345 #/hr, it has an s stamp and a national board
number. The installer attaches a new tag that says the heating surface is 50 sq.
ft. and has a Btu input of 300,000 + Btu/hr (not sure of exact number). As chief of
this plant, what is real hp and how do you know which tag is correct? (Chapter
146).

15. List 4 turbine trips not generator trips.

16. List 6 causes of turbine vibration?

17. You come across a thrust bearing that is reading 145F where normally it
has been 130F. what do you do?

18. Explain the operation of a Kingsbury thrust bearing (drawing is optional).

19. Name three ways to determine safety valve capacity?

1.) Conduct an over speed trip on a turbine.

2.) How do you calculate water rate?

3.) You have 52 barrels of fuel oil with a specific gravity of .85. What does the
fuel weigh? (1 gallon of water weighs 8.33 lbs).

4.) What does ANSI 31.1 say about blow off valves and piping on a boiler with
an M.A.W.P. of 125 PSI?

5.) What is the factor of safety of a boiler with an M.A.W.P. of 275 PSI that has
a safety valve set at 150 PSI? The old factor of safety was 4.

6.) When a process goes through volume and pressure variations but no
temperature changes is called?

7.) Describe the construction and operation of a Kingsbury Thrust Bearing.

8.) Which turbine has more end thrust Impulse or Reaction and why?

9.) What is Water Hammer and how do you prevent it and remedy it?

10.) A direct stay 1 in diameter is attached to a flat surface of an HRT boiler.

Would the diameter of a diagonal stay be supporting the same area? The
diagonal stay is 60 in length and the length of the line drawn at a right angle to
the surface supported is 48 (Answer is PFT 32 ASME Code Section one)

11.) What is the horsepower of a 1000 Kilowatt Generator?

12.) When a process goes through Volume and Pressure variations but no
temperature change occurs this is known as? (Yes the question was repeated on
the second page of the test).
 13.) How do we calculate Turbine horsepower and what is water rate used for?
(Yes, second water rate question).

14.) What is the first law of Thermodynamics?

15.) Calculate the M.A.W.P. for a boiler 60 in diameter, having thick plate,
with a tensile stress of 11,000 and a joint efficiency of 80%? Use p=.8SET/R + 6T

16.) Explain Factor of Evaporation and what is it used for?

17.) Define the following; Tensile strength, Elastic limit, Yield point, Elongation
and Reduction of area?

18.) A.) What is minimum relieving capacity of an electric boiler operating at 512
Watts?

1. How would you remove a failed weld to repair it?

2. Describe what a convergent-divergent nozzle is. Why is it used?

3. Why do you have multiple throttle valves?

4. What is galvanic corrosion? How would you prevent it?

5. An oil has a weight of 7.398 pounds per gallon. What is the specific
gravity of the oil? Water weighs 8.34 pounds per gallon.

6. Name six losses of a turbine (do not list loss to the condenser).

7. Can you have a nozzle in a welded joint?

Can you roll a tube in a hole in a welded joint?

8. A condenser losses vacuum gradually after six months. List 6 causes.

9. What is water rate?

10. List and describe all auxiliaries for a condensing turbine.

11. What is a flexible coupling on a turbine? Describe a gear or dental type.

12. What is specific heat?

13. When you hydro a boiler you must:

 14. What is the boiler efficiency of 10,000 #/hr boiler producing 150 psig at
100% steam quality and feed water temperature of 212F. Fuel is fed at 700
pounds per hour with a Btu content of 80,000.

15. What is Net Positive Suction Head? What is "actual" and "required"?

16. List three signs of an overheated bearing.

17. What is oil-ash corrosion?

18. Stay bolt question?

19. What are the classes of boilers?

What is the least amount of appliances on a boiler for safe operation?

20. What two principles are turbines designed for?

1. What can u do w/a 2nd engineer license?

2. What is the difference. between inner crystalline & trans crystalline cracks in
boiler

metal? What causes these kinds of cracking? explain fully

3. List 5 destructive test for welds. list 5 non-destructive tests

4. A horse power of a boiler has a MAWP of 800 psi. what is the minimum
pressure rating required by

code for the source of water to the boiler?

5. When are backing rings required by code and can they be left in place or
removed?

6. What is the difference between a once through and a super critical steam
generator? What are the temperature and pressure that define a super critical
steam generator?

7. Name 3 advantages and disadvantages of using a High Temperature Water

heating boiler?

8. Explain where you would use the following non destructive exams?
radiography
magnetic particle test
eddy current test
ultra sonic test

9. What is an oscilloscope and where would you use it?

10. Name 6 factors to consider for heat treatment procedures?

11. How are allowances for expansion in steam piping commonly achieved?
Name 3 ways?

12. 5 ways of controlling super heat temperature?

13. A boiler has 400 psi on it. it's 2.5"diam. What is the force on the valve disc?
show all work!

14. A question on federal and local air emissions.

15. How do you determine the relieving capacity of a separately fired super
heater?

16. Determine the stress of 4 bolts problem??

17. What is oil whip? What causes it? Explain fully.

18. Delong's formula problem. Coal sample taken with all percents given.

19. Equivalent evaporation problem?

1. You have to install a blow down line on a high-pressure boiler what

requirements, for pipe size, valves, and material used? What volume in gallons
and what pressure rating would you specify for the tank to meet the minimum
requirements of the National Board Inspection Code?

2. How do you find boiler efficiency?

3. Three ways to purify water?

4. Define elastic limit, yield point, elongation, and relative loss.

5. Three ways to reduce stack emissions and how they work?

6. Name at least 6 losses in a turbine?

7. Name four trips on a turbine?

8. Describe a Kingsbury thrust bearing and its operation?

9. Atmospheric pressure is 29.92 in hg. Vacuum gauge reads 22 in. hg. What is
the absolute pressure?

10. What are over the fire air jets used

for two uses?

11. Safety valves and safety relief valves what are the differences?

12. You have two pumps and one tank, one pump can empty the tank in 6 hours
the other in 5 hours. How long would it take if both ran?

13. You have 52 barrels of #6 oil with a specific gravity of .85 at 60 degrees.
What is the weight of the oil?

14. Two types of air heaters

15. Are temperature changes or pressures more harmful to a boiler, and why?

16. What is the efficiency of a boiler 150psig 100% quality, 10,000 lbs /hr fuel 700
lbs, 18,000 btu lb.

17. How is steam flow measured?

1. What is the horsepower and water rate of a theoretically perfect turbine

operating at 175 psi and exhausting to a condenser at 28.9 Hg. Steam is
supplied at 1000 pounds per hour? ( h1 = 1187), (h2=895), (h3= 10.5).

2. What is the difference between engine horsepower and boiler

horsepower?

3. What is galvanic corrosion, and how do you prevent it?

4. What types of couplings are used on a turbine shaft?

5. What two adjustments can be made on a safety valve, and who can do
it?

6. A.) How do you know a welder is qualified? B.) How long does the
qualification last? C.) Who keeps records and is responsible for testing?

7. Find the BTU content of a coal sample with, c 85%, 02 5%, H 5%, S 1%
N 3%, A 1-%?
8. Who tests the coupons sent in by the welders?

9. Name 6 reasons for gradual vacuum loss?

10. Name 4 reasons for a 150,000 LB / hr boiler to only produce 133,000

LB/hr?

11. According to fan laws if speed increases what happens to A. volume, B.

pressure, and C. horsepower?

12. Define heat treatment and stress relieving?

13. A boiler fired with coal with a BTU value of 18,500 per lb. burning 1150
lb./hr at 82% efficiency what is the total BTU loss'?

14. State the procedure for blow down tank installation? Explain fully.

15. The company with a spool piece has reduced a turbine with a six-inch
inlet to four inches. Who can operate and take charge this turbine in accordance
with chapter 1467

16. What is a separating calorimeter and how does it operate?

l 7. List environmental, concerns and limits of a boiler according to the law?

18. Why do you test coal in a power plant?

19. What test can be done for a leak on a pressure vessel?

20. What is a syncroscope and how does it operate? Explain in detail.

1. Name 4 safety devices on a gas turbine?

2. Name 5 Non-destructive tests and briefly describe.

3. Name 3 trips on a steam turbine and how they are connected.

4. 2000HP boiler, 200PSI, pump efficiency 85%,What's the pump HP?

5. Blades 48in., 400RPM, What is the steam speed in relation to blade speed
with steam traveling @ 11,900 ft/min?

6. 6 inch inlet company wants to install a 4 inch. spool who can have charge of
this according to Chap. 146?

7. Define NPSH. What is actual and required?

8. What does a company need that performs welding on a boiler?

9. What are the duties of an engineer in charge? What license do you need if it's
a 2nd class plant?

10. Define stress corrosion crack.

11. 8 things to consider before installing an economizer?

12. How would you remove a rotor without bumping it?

13. Fans Laws: Fan speed increases, What happens to the volume of air, total
pressure, and horsepower?

14. How would you figure safety valve relieving capacity on a super heater?

15. What info can you find on a Mollier Diagram?

16. What is a spindle or dummy micrometer?

17. Name 3 ways of controlling NOX.

18. What is creep?

1. Give 7 reasons for heat loss in a boiler.

2. List 4 protective devices on a GAS turbine.

3. How long must the radiographs be kept on file by the manufacturer for power
boilers?

4. How do you align the shaft of a small turbine feed pump and explain how to
check it?

5. Give 3 ways you can tell the bearings on a turbine are overheated.
6. Why does the auxiliary lube oil pump continue to operate even after the turbine
has been secured?

7. Pipe up an extraction line for safety.

8. A boiler generates 20,000 lb/hr and has a factor of evaporation of 1.24. What is
the developed boiler horsepower?

9. What is a dry bottom furnace, and a wet bottom furnace?

10. What is an exciter explain how it works?

11. How is scrap metal prevented from entering the pulverizer when burning
pulverized coal?

12. Define net positive suction head. What is required and actual net positive
suction head?

13. Describe thermal efficiency of a turbine with bled steam heating feed water
at various stages.

14. List the steps for starting a turbine driven feed water pump.

15. Why are multi inlet valves used explain in detail?

16. Give 4 reasons for loss of vacuum in a surface condenser and give the
remedy for each.

17. How is dye penetrate used?

18. Describe the operation of a Hydraulic Governor be very clear and specific
use a drawing if necessary.

19. Surface condenser vacuum is 27" the barometer reads 29.8". What is the
absolute barometric pressure and absolute psi.

20. What is the M.A.W.P. of a cast iron water column?

1. Match the terms with the definitions. All definitions given. A. Erosion, B.
Corrosion, C. Enthalpy, D. Entropy, E. Tensile strength, F. Tensile stress, G.
Fatigue, H. Fracture.

2. Match the terms with the definitions. A. yield point B. toughness C

malleability D. elastic limit. E. Buckling F. Plastic deformation. G. Creep H.
Torsion Stress. All definitions given.

3. Match the terms with the definitions. A. Inductance. B. Resistance. C.

Capacitance. D. Magnetism. E. Potential difference, H. work, I. Heat J. Therm.
All the definitions are given.

4. At what temp and pressure does a boiler have to operate at to be considered

a Power Boiler under the ASME code for Power Boilers?

5. What are six causes of turbine vibration?

6. What is the purpose of shroud bands on gas turbines and on steam

turbines?

7. What is meant by blowdown on a safety valve? What is the minimum and

maximum blowdown on a steam safety valve?

8. What is the popping point tolerance for a 250lb. Steam safety valve?
9. A picture of a thrust bearing, what kind is it? And describe its construction
and operation.

10. What are six ways a surface condenser will gradually loose vacuum?

11. On a turbine, the control valves are operated by a beam driven by a cam
gear. How does this reduce throttling losses explain fully?

12. Explain what happens to the steam pressure and velocity in each part of a
velocity compound Curtis Stage?

13. The third law of Thermodynamics is. A. Newton's Law, B. Boyls Law, C.
Charles Law, D. Boltzmens Law.

14. Who is qualified to change the set pressure on a steam pop safety valve?

15. Can a qualified welder do any welding repair on a boiler? Explain fully.

16. Define fully the term Rotor Long.

17. What would cause a turbine shaft to be bowed? A. Turning gear binding, B.
Improper cool down of the turbine, C. D.

18. How much expansion on a beam 33 feet long 50 degree Celsius raise
coefficient is ten times ten to the negative six?

19. What is the BDHP with steam at 1200 btus. 150,000 steam flow, and feed
water 230 degrees. Factor of evaporation is not known.

20. A boiler generates 5,000,000 lbs. Of steam per day. The CBD blowsdown
5%. The temp of the feed water is 400 degrees. How much water is blown down
per day, and what is the BTU loss?

1. What is the purpose of a syncroscope?

2. What is the difference between an ultimate and a proximate analysis?

3. Name the major boiler losses. (Seven)

4. What are the probable causes for a surface-condensing turbine to gradually

lose vacuum?

Name at least five. (Asked twice)

5. A boiler is rated for 150,000 pounds of steam per hour, but only produces
135,000 pounds per hour. List four (4) probable causes.
6. A turbine operates at 100% efficiency. The steam is supplied at 175 psig,
exhausts at 28.5 inches Hg. The turbine uses 1,000 pounds of steam per hour.
What is the horsepower and water rate? (Given h1=1,197; h2=851; hf2=105).

7. How is the Thermal Efficiency of a turbine affected by bleeding steam to heat

the feed water?

8. What information is listed in the Daily Record book that is published by the
Massachusetts Department of Public Safety?

9. What is the difference between Active and Inactive pitting?

10. How are the bearings aligned in a Turbine Generator?

11. What is the theoretical discharge pressure of a pump from 1,800 RPM at 100
PSI to 3,000 RPM?

12. What is the difference between static and dynamic balancing?

13. Name at least six turbine losses? Do not use the condenser in your answer.

14. Name five reasons for a pressure drop in a Number 6 fuel oil line.

15. Start a small condensing turbine.

16. There are two 300 HP boilers in separate locations in the same plant. Can a
third class engineer take charge? If the boilers are in battery?

17. A Company wants to insert a spool piece to change the steam inlet to the
turbine from 6 to 4. What license is necessary to be in charge?

18. What are the requirements for a company to do welded repairs in

Massachusetts? How are these requirements met?

19. What is the purpose of a vacuum pump in a vacuum heating system and
why is such a heating system used?

1.) What is the efficiency of this turbine using the Rankine Cycle? 200 PSIA,
600o F, 1" back pressure, rated at 10.5 per horse power hour.

2.) How many expansions take place with steam at the following conditions?
Steam pressure 400 PSIA & Vacuum 29 ". Steam tables given.

3.) A boiler burns #6 fuel oil with a heating valve of 146,000 BTU's a gallon.
Steam at the boiler outlet has 1200 BTU.s, feed water temperature is 210o F .
Combustion efficiency is 82 %. How many lbs of water can be evaporated per
gallon of fuel?

4.) Describe a mixed bed deminerlizer?

5.) What is a exciter and describe its operation.?

6.) Describe how to synchronize a generator?

7.) Order a safety valve.

8.) Find the thickness of a head with the pressure on the concave side when it is
the segment of a sphere with a flanged in manhole? Given: 300 MAWP, 40"
Diameter, Stress = 13,700, PG 29.3 states thickness shall be increased by 15%

9.) How can a boiler tube carry such high pressure with such thin walls? Prove
by this formula for a longitudinal

10.) Given the pitch the tube diameter and hole diameter. What is the ligament
eff?

11.) Describe the operation of a three element feed water system?

12.) What is the ASME Code for (boilers) and what is the National Board for?

13.) Name four causes of loss of vacuum and how to correct them?

14.) How much heat is lost to the condenser given the following? Given: Inlet
pressure & temperature, vacuum, barometer and they gave a figure of 1050
BTU's at exhaust.

15.) Why do we have multiple valve governors? Explain fully.

16.) What is the purpose of a extraction turbine grid valve? Explain fully.

17.) A turbine uses 40,000 lbs of steam a hour and a output is 2,000 KWH. What
is the water rate?

18.) With respect to corrosion deterioration, what is grooving and where would
you find it?

19.) What can you do with this license?

20.) What is a fluidized bed boiler? What is its advantage?

1.) OHM'S Law, Describe (definition), and show symbols and the meaning of
each?

2.) What are the mean part of a A.C. Generator?

3.) What is an Exciter? What is it's purpose and what would happen if you lost
excitation?

4.) Xfoliatio, what is it? Explain fully. What does it affect? What problems would
it pose?

5.) Safety valve nozzle reaction type, what would happen should the orifices
become obstructed?

6.) How may corrosion around manholes and hand holes be repaired? What are
the limits?

7.) Describe the losses in a turbine?

8.) Explain the operation of a sodium exchanger also a deminerlizer.

9.) Dalton's law, what is it?

10.) How much efficiency is gained by using a Topping Cycle?

11.) How come a non-condensing turbine will show a higher efficiency than a
condensing turbine?

12.) A coal bunker contains 20,500 ft3 of coal. What is the weight of the coal in
pounds?

13.) A steam supply line is to carry 10,000 lbs / stm / hr @ 200 psi, the volume of
the steam @ 200 psi is 2.2893 ft3, what is it's velocity? What diameter of pipe
would be required?

14.) How would you figure the ratio between a reaction vs. Curtis stage in a
turbine?

15.) A boiler contains 500 water wall tubes, each tube is 20 ft long and 4 inch
diameter. The convection section contains 1200 tubes 4 inch by. What is the
heating surface in ft2

16.) Name five types of non-destructive tests. Explain two.

17.) A 275 horse power boiler is producing steam at 100 psi, burning #6 fuel oil
18,500 btu / lb. Factor of evaporation is 1.12 and the boiler is 80% eff. What is
the evaporation rate and HP. ?

18.) 500 lbs of water @ 1500 and 300 lbs @ 900 are mixed together, what is the
final temperature of the mixture?

19. Why are welded joints stronger than the metals they have joined? What
happens during the welding process?

20.) Steam pressure at a turbine inlet is 950 Pisa it exhaust to the condenser @
1.5" hg. What is the number of expansions?