Block 2 - Commission Fuel Train Components & ICI Burners Self Assessment

Question 1

According to ASME CSD1, where is the installation of a strainer recommended in the gas train?

Answer 1

Before the horizontal components

Question 2

How are oil burner valve trains different from gas fuel valve trains?

Answer 2

Oil valve trains often combine components into an “oil block”

Question 3

Where should a high gas pressure safety device be installed according to B149.3 clause 12.5.1?

Answer 3

Downstream of the pressure regulator

Question 4

What is the purpose of the low gas pressure safety device according to B149.3 clause 12.5.2?

Answer 4

To initiate shut off of the gas supply if pressure drops below 50% of the lowest normal operating pressure

Question 5

How is fuel adjusted on a burner with a fuel cam?

Answer 5

By changing the position of the input flow control valve

Question 6

Which type of VPS uses a pump and advanced instrumentation?

Answer 6

Active VPS

Question 7

What should be checked to ensure gas-tightness of the valve seats according to B149.3 clause 15.1?

Answer 7

1) Appliance shutoff valve

2) Test firing valves

3) SSOV valves

Question 8

What is the purpose of the overtravel linkage on a fuel cam system?

Answer 8

To set and lock high fire and low fire stops

Question 9

What is the first step when checking the tightness of closure of a fuel valve?

Answer 9

Install a manometer or pressure gauge

Question 10

Which clause in B149.3 specifies the outlet pressure maintenance capability of a pressure regulator?

Answer 10

Clause 4.4

Question 11

What is a suitable option for selecting overpressure protection (OPP) when high inlet pressure is encountered?

Answer 11

Monitor regulation

Question 12

What is the required accuracy of a pressure regulator outlet pressure during burner operation?

Answer 12

Within 10% above or below the regulator set pressure

Question 13

When adjusting a flow control valve, what tool should be used to ensure accurate adjustments?

Answer 13

Combustion analyzer

Question 14

For appliances with inputs in excess of 400,000 Btu/h (120 kW), where should a low gas pressure safety device be installed?

Answer 14

Downstream of the pressure regulator and upstream of the safety shutoff valve

Question 15

What is a common feature of the SSOVs in oil burner valve trains?

Answer 15

Normally closed solenoid valves piped in series and wired in parallel

Question 16

Which system allows precise adjustment to a single valve or damper position without affecting other components?

Answer 16

Parallel Position system (FARC)

Question 17

What action is recommended if a fuel valve leakage is detected?

Answer 17

Correct any conditions causing leakage

Question 18

What is the purpose of the B149.3 Annex A procedure?

Answer 18

To ensure safe start-up of high input gas-fired equipment

Question 19

Which type of valve shall be of the quarter-turn type according to B149.3 - 6.2?

Answer 19

Test firing valve

Question 20

What does a modern unified valve combine into a single device?**

Answer 20

1) Pressure regulation

2) Valve closing

3) Variable flow rate and pressure switch

Question 21

What is the opening time for electro-hydraulic SSOVs?

Answer 21

13 seconds or 23 seconds

Question 22

What is the purpose of the Proof of Closure switch?

Answer 22

To prove the valve is in the closed position

Question 23

What is the purpose of the FGR flow control damper?

Answer 23

To regulate the quantity of flue gas to the FGR inlet box

Question 24

When setting FGR rates, why are two emissions analyzers required?

Answer 24

To measure the stack O2 levels, CO, NOx emissions, and oxygen content in the burner housing

Question 25

What is the purpose of the FGR flow control damper?

Answer 25

To regulate the quantity of flue gas to the FGR inlet box

Question 26

How should the draft be adjusted if it is too low during commissioning?

Answer 26

Add weight to the damper chain to choke dilution air and increase draft

Question 27

What is primary air in the context of combustion?

Answer 27

The air supplied to achieve stoichiometric combustion

Question 28

Why is it important to insulate the duct, FGR damper, and inlet box assembly?

Answer 28

To prevent accidental burns in high-temperature areas

Question 29

What is the purpose of adjusting fan speed during combustion optimization?

Answer 29

To find the optimal point where combustion is efficient and stable

Question 30

What is the role of the PID gain settings in an integrated or standalone draft control system?

Answer 30

To adjust for the correct draft and set response and accuracy if modulating

Question 31

Why is it important to have provisions to drain condensate in the FGR system?

Answer 31

To prevent water vapor accumulation and condensation in low points

Question 32

How should the stack temperature switch be set during FGR system start-up?

Answer 32

A few degrees below the normal low fire stack temperature (approximately 200°F)

Question 33

What effect does a positive combustion chamber pressure have on the system?

Answer 33

Adds a closing force on the regulator, upsetting control of the system

Question 34

What should be confirmed before operating the burner for an extended period?

Answer 34

The FGR blower is in operation

Question 35

What is the primary function of the FGR inlet box?

Answer 35

To pull flue gas from the stack and deliver it to the combustion air fan inlet

Question 36

What should be the maximum pressure drop between the stack and burner inlet in the FGR ductwork?

Answer 36

1-inch w.c.

Question 37

What should be tested and set to correct settings during operating and limit controls check?

Answer 37

All operating and limit controls

Question 38

What should be confirmed before performing a combustion analysis?

Answer 38

Drafts for the appliance are correct

Question 39

What should be done if the low fire light off position results in noticeable physical vibration of the equipment?

Answer 39

Decrease the burner firing rate

Question 40

When setting FGR rates, why are two emissions analyzers required?

Answer 40

To measure the stack O2 levels, CO, NOx emissions, and oxygen content in the burner housing

Question 41

What should be done if the low fire light off position results in noticeable physical vibration of the equipment?

Answer 41

Decrease the burner firing rate

Question 42

What should be done if temperature and pressure variations in the boiler room prevent repeatable operation of the burner?

Answer 42

Add control components such as oxygen trim

Question 43

What should be done if clocking is not possible due to other appliances firing?

Answer 43

Install an orifice plate

Question 44

Why is an impulse line used in combustion systems?

Answer 44

To connect the combustion chamber to the air/gas ratio regulator, correcting regulator action

Question 45

What is the main goal when setting the high fire air/gas ratio in a zero governor system?

Answer 45

To achieve the correct high fire setting using a limiting orifice

Question 46

What is the function of the FGR duct temperature switch?

Answer 46

To shut down the burner if duct temperature exceeds the set point

Question 47

Why is it important to perform a pilot turn down test?

Answer 47

To ensure the smallest pilot flame will ignite the main flame safely

Question 48

What should be confirmed before showing up on-site for commissioning an appliance?

Answer 48

All appropriate permits are in order

Question 49

Why is it important to note the stack temperatures during commissioning?

Answer 49

To compare them to the manufacturer's specifications

Question 50

Why is it important to insulate the duct, FGR damper, and inlet box assembly?

Answer 50

To prevent accidental burns in high-temperature areas

Question 51

How should FGR damper position adjustments be made, especially at low firing rates?

Answer 51

In very small increments while observing readings and burner operation

Question 52

What should be the maximum pressure drop between the stack and burner inlet in the FGR ductwork?

Answer 52

1-inch w.c.

Question 53

What should be done if temperature and pressure variations in the boiler room prevent repeatable operation of the burner?

Answer 53

Add control components such as oxygen trim

Question 54

Why is it essential to prove the stack damper is open before allowing the combustion air blower to start?

Answer 54

To ensure safety and proper operation of the system during the purge sequence

Question 55

What information does a gas safety officer need to check permits?

Answer 55

Customer name, company site name, and address

Question 56

What should be confirmed before operating the burner for an extended period?

Answer 56

The FGR blower is in operation

Question 57

How should the air damper position be adjusted if the system uses linkages?

Answer 57

Adjust in increments of 10% using a potentiometer

Question 58

What is the function of the FGR duct temperature switch?

Answer 58

To shut down the burner if duct temperature exceeds the set point

Question 59

How should initial airflow be set during commissioning?

Answer 59

By adjusting the air damper(s) or fan speed

Question 60

How should the stack temperature switch be set during FGR system start-up?

Answer 60

A few degrees below the normal low fire stack temperature (approximately 200°F)

Question 61

When adjusting initial damper positions, why is it important to follow the manufacturer's recommendations?

Answer 61

To achieve proper air-fuel mixing and combustion stability

Question 62

What is the primary function of the FGR inlet box?

Answer 62

To pull flue gas from the stack and deliver it to the combustion air fan inlet

Question 63

What should be checked during a site visit ahead of time?

Answer 63

Gas piping size, pressure, and testing

Question 64

Why is it important to have provisions to drain condensate in the FGR system?

Answer 64

To prevent water vapor accumulation and condensation in low points

Question 65

How should FGR damper position adjustments be made, especially at low firing rates?

Answer 65

In very small increments while observing readings and burner operation

Question 66

Which of the following should be verified with gas firing valves closed?**

Answer 66

Prove high fire purge