2nd Grade Hard Questions

Question 1

What is condensate polishing?

Answer 1

High pressure system uses an ion exchange system that can withstand high temperatures to purify condensate before it returns to the boiler.

Question 2

Name three types of corrosion in a cooling tower.

Answer 2

Water hardness, pH, and algae. SPO 6th 549

Question 3

What is a polisher?

Answer 3

A polisher is an ion exchange process which is used to remove trace contaminants both dissolved and suspended from high purity water.

Question 4

What is a demineralizer?

Answer 4

Highly efficient ion exchange water softener that uses sulfuric acid and caustic soda in the regeneration process. It removes silica, CO2, chloride and sulfate. A demineralizer removes practically all dissolved solids in water.

Question 5

What’s the lowest condensate pH should be?

Answer 5

8.3

Question 6

What causes freeze back on an ammonia compressor?

Answer 6

Improper charge or improper operation of metering device.

Question 7

How do you test for leaks in an ammonia system?

Answer 7

Sulfur sticks, phenolphthalein, foams, litmus paper. A burning sulfur candle will produce white smoke at the leak.

Question 8

How are gasses formed in an ammonia system?

Answer 8

Heat is absorbed in the evaporating coil which causes the liquid to boil until vaporization is complete.

Question 9

Explain the purpose of the accumulator and how it works.

Answer 9

It is a safety device that prevents the compressor from slugs of refrigerant; it is placed in the suction line, so any liquid that flows into the accumulator will be evaporated before entering the compressor.

Question 10

In refrigeration what is the last thing you check before connecting your test gauges?

Answer 10

You should check for which is the high pressure side and for the low pressure side of your system.

Question 11

What types of compressors are used in a Freon system?

Answer 11

Centrifugal, rotary, reciprocating, scroll, screw.

Question 12

What is a purger and where is it located on a refrigeration system?

Answer 12

A device used to remove air and non-condensable gases from the system, located at the highest point in the system.

Question 13

Describe the operation of an 8 blade rotary compressor and be prepared to draw one.

Answer 13

The eight blade compressor is an external drive commercial unit. A rotor with eight floating blades that are off set inside the cylinder, as the rotor spins, low pressure vapor from the intake ports fill the spaces between the blades. The trapped vapor is compressed and pushed into the exhaust ports.

Question 14

How does an evaporator condenser work?

Answer 14

An evaporator consists of a steam coil in a tank. Water is fed to the tank and a float maintains a constant level. A pump circulates and sprays water over the refrigeration condenser. A fan draws in air through the side of the evaporative condenser housing and forces air out the top. Water droplets are cooled by evaporation and flow over the condenser.

Question 15

Regarding refrigerant EPA compliance regulations name five?

Answer 15

Written mission statement for compliance, policy on detailed record keeping, written purchasing, labeling and handling policy, storage and inventory policy, leak test policy.

Question 16

In regards to refrigeration what is superheat?

Answer 16

Temperature of vapor above its boiling temperature as a liquid at that pressure.

Question 17

What damage can happen if a turbine is started to quickly?

Answer 17

The wheels and dummies may distort through uneven expansion.

Question 18

What’s a reaction turbine and what’s it used for?

Answer 18

It is designed so there is considerable expansion in the rotating blades. Used for extraction for other pieces of equipment.

Question 19

What is power factor?

Answer 19

The ratio between the apparent power and the actual power in an AC circuit.

Question 20

What are the essential steps in putting on a cold boiler on line with other operating boilers?

Answer 20

Blow down gauge glass and water column, open vent on boiler drum, start the burner on a low manual fire, test flame scanner, test low water cut off, when boiler builds pressure close the vent, open header valve drain and non-return valve drain, open equalizing line to warm header, when boiler pressure is 80% of header pressure open header valve and close the drain, Unscrew the hand-wheel on the non-return valve and close the drain, when boiler pressure equalizes put controls in automatic.

Question 21

Name three types of oil burners?

Answer 21

Rotary, Steam or Air, Pressure. SPO 6th 201

Question 22

How to operate soot blower on a manually operated water tube boiler?

Answer 22

Run soot blower with a manually operated chain drive.

Question 23

What are two types of welds on boiler construction and repair?

Answer 23

(SAW) Submerged Arc Welding; (OAW) Oxyacetylene Welding; (SMAW) Shielded Metal Arc Welding

Question 24

Sketch a steam header valve arrangement.

Answer 24

Draw boiler, non return valves with drains, then header

Question 25

Name two low water cutoffs tests and how often should you test them?

Answer 25

Evaporation test and slow drain test; test them yearly or during an outage.

Question 26

When should you bottom blow a boiler? What safety procedure must be followed when bottom blowing a boiler?

Answer 26

When starting up with a small amount of pressure on it, but only when the fires are out. Always be in control of the valve.

Question 27

How is a steam gauge connected to a boiler? What are two requirements?

Answer 27

Connected to the steam space of a boiler by a siphon, should be made of copper or brass and the shutoff should be located near gauge.

Question 28

Why is welding preferred over riveting on longitudinal?

Answer 28

Welded longitudinal joints are stronger than riveted joints, welding eliminates areas where sludge can form

Question 29

Why are tube ends beaded over in a steam drum?

Answer 29

To make sure they get completely drained and to prevent air from being expelled.

Question 30

How do you do a dry boiler layup?

Answer 30

When the boiler pressure has dropped to 100 psig it is treated with sodium nitrate and filled to the top of the boiler gage glass then drained or Desiccant lay up method uses bags of desiccant to keep the boiler dry.

Question 31

How do you do a wet boiler layup?

Answer 31

Boiler should be filled completely to the top with deaerated water, add sodium sulfite to 250 ppm for an oxygen scavenger, to control ph add caustic soda to 450 ppm.

Question 32

Inverted bucket trap?

Answer 32

inverted bucket steam trap can be made to withstand high pressures, Can be used on superheated steam lines with the addition of a check valve on the inlet, used on turbine drains.

Question 33

How does a centrifugal pump eliminate balance problems?

Answer 33

Through the use of balancing devices to control and indicate flow in a return line, thrust bearings, double flow impellers.

Question 34

Name three things vacuum pump does for heating system?

Answer 34

remove non-condensables, increases efficiency over ejector, good at moving gas and liquid.

Question 35

Name three merits of a metering pump.

Answer 35

A wide variance of delivery volume, capable of a pumping a wide variety of chemicals and generally used for heads above 200 psi.

Question 36

How high will the suction of a single stage centrifugal pump lift water?

Answer 36

Cold water 10-15 ft. hot water should come to the pump at a positive head.

Question 37

What are two types of vacuum pumps?

Answer 37

Rotary and centrifugal. SPO 6th 347, 350

Question 38

What are the requirements of a good motor?

Answer 38

Three phases, variable frequency drive, soft start feature.

Question 39

Manifold duplex water pumps?

Answer 39

Used for boiler feed service and is capable of handling water at high temperatures without cavitation. They are operated by two float switches set to start the water pumps at low and high water levels in the receiver. SPO 6th 345

Question 40

What is meant by on-off, positioning, and metering control?

Answer 40

On/off is the basic type of control, then positioning is where there is more selection than just on/off, and metering control is more accurate than positioning.

Question 41

Dealing with water column piping what is, maximum and minimum diameter?

Answer 41

Minimum 1”, Maximum 2 ½”, blow off line ¾”.

Question 42

Fire safety plan?

Answer 42

Goals and priorities of the plan are to have basic awareness and appropriate response to; understanding what fire is, fire in your area, types and how to react, fire exit and drills, location of extinguishers and fire hoses, escape routes, rescue plans.

Question 43

What are five basic methods used for protection of cross contamination of potable water

Answer 43

(1.) Air gap, no less than 1” and no more than 2 times the diameter of the pipe. (2.) An atmospheric style vacuum breaker (3.) a pressure style vacuum breaker (4.) reduced pressure style back flow preventer (5.) double check valve assembly.

Question 44

Which way should a steam line slope and why?

Answer 44

Horizontal runs must slope in the direction of steam flow with steam traps at all points where water may accumulate lessens the chance of water hammer. SPO 6th 582

Question 45

What is a seat less plug blow down valve?

Answer 45

A seat less valve, in the body it permits pressure to surround the plunger, making the valve fully balanced and hence easy to operate at all pressures. SPO 6th 256

Question 46

What are two problems if soot blowers discharge water?

Answer 46

Avoid slugs of water which might damage blower and erode the tubes.

Question 47

What is the lining for inside a steel stack?

Answer 47

Help protect the stack form erosive particulates and corrosive action from acid and flue gas.

Question 48

What is lagging? And how does it affect efficiency?

Answer 48

Lagging is an outer covering over a wall used for protecting the insulation from water or mechanical damage. To provide safety for personnel and minimize heat loss, thus improving efficiency.

Question 49

Describe an intercooler and after cooler on compressors?

Answer 49

An intercooler is designed to remove heat from the compressed air in between stages on a multistage compressor. An after cooler is a component that cools compressed air coming from the last stage of a compressor and also removes moisture.

Question 50

If an underground fuel tank has 5,000 gallons in it already and it is a 10,000 gallon tank, how much would you order and show your work.

Answer 50

Underground tanks can only be filled 95% full. So 10,000 gal x .95 = 9,500 gal; 9,500 – 5,000 = 4,500 gal

Question 51

TDS

Answer 51

Total Dissolved Solids is a measure of the total ions in solution.

Question 52

Conductivity

Answer 52

of a substance is defined as 'the ability or power to conduct or transmit heat, electricity, or sound'.

Question 53

List 6 things printed on Badge Plate on a boiler?

Answer 53

(A) Design Steaming Rate (B) Boiler Design Pressure (C) Boiler Operating Pressure (D) Boiler Operating Temperature (E) Economizer Design Pressure (F) Economizer Design Inlet Temperature

Question 54

How big would the blowdown tank vent line be?

Answer 54

It should be big enough so the tank pressure doesn't exceed 10 psi.

Question 55

Convert 15 degrees Celsius and show work.

Answer 55

(9/5 x 15C) + 32 = (9/5 x 15/1) + 32 = (9 x 3) = 27 (27) + 32 = 59 degrees Fahrenheit

Question 56

Convert 77 degrees Fahrenheit and show work.

Answer 56

(77F - 32) x 5/9 = (45) x 5/9 = 45/1 x 5/9 = 5 x 5 = 25 degrees Celsius

Question 57

Draw a water column with low and high alarms and a whistle.

Answer 57

Draw drum with water column on side of it with high and low alarms and a whistle at the top of water column.

Question 58

How is pressure controlled on a boiler when multiple boilers share the same header?

Answer 58

Describe theory of equaling out boiler feed pumps, by using “leading and Lagging”.

Question 59

There are about five questions about centrifugal pumps and what types of fittings would you use and what type of pipe, eccentric or concentric?

Answer 59

You want to weld the fittings so there is no possible leakage of air into the pump to possibly cavitate the pump. Also always use eccentric piping before a centrifugal pump so there is no chance of cavitation. The point in all of these questions is to keep a centrifugal pump air tight so there is no cavitation. An eccentric reducer is mostly used to force air in a direction, normally towards a pump or air valve so that it does not get trapped inside the pipework. To allow for proper drainage in a steam system or sometimes to maintain a wet return. This is related to the question above. A concentric pipe has equal angles on each side: eccentric is angled on one side and flat on another. The use of the concentric would allow air to enter the pump with the eccentric having a flat side there is no chance of air entering the pump.