Block 2 - Maintain Boilers & Ancillary Equipment

Question 1

What is the average annual fuel consumption of a boiler compared to its initial cost?

Answer 1

More than four times its initial cost in fuel every year.

Question 2

What is the primary purpose of a boiler inspection?

Answer 2

To provide assurance of equipment integrity and minimize safety issues.

Question 3

What is a secondary function of boiler inspections?

Answer 3

Acting as an early warning of potential problems.

Question 4

What is the minimal inspection frequency for boilers established by law?

Answer 4

It is established by law and the insurance company covering customer liability.

Question 5

How often should the pressure vessel waterside be inspected after initial operation?

Answer 5

Three months after initial starting and at regular 6-, 9-, or 12-month intervals.

Question 6

True or False: Steam boilers typically require an internal inspection once every two years.

Answer 6

False. They require an internal inspection once per year, at a minimum.

Question 7

What can lead to pitting, corrosion, and formation of sludge in hot water systems?

Answer 7

Introduction of raw water make-up or air.

Question 8

What is the responsibility of the equipment owner and operator regarding boiler maintenance?

Answer 8

They are responsible for performing maintenance on the required schedule.

Question 9

What must be done to prepare equipment for inspection by a safety officer?

Answer 9

Remove jackets, perform non-destructive tests, open and clean every boiler or pressure vessel.

Question 10

What is the leading cause of deterioration of pressure vessels?

Answer 10

Improper water treatment.

Question 11

What should be regularly checked to confirm the success of the boiler water treatment?

Answer 11

Boiler water chemistry.

Question 12

Fill in the blank: The waterside of the pressure vessel must be kept clean from _______.

Answer 12

grease, sludge, and foreign material.

Question 13

What should be done if excessive mud or sludge is noticed during the blowdown?

Answer 13

Revise the scheduling or frequency of blowdown.

Question 14

What should every boiler inspection start with?

Answer 14

A complete visual inspection of the exterior.

Question 15

What are the safety guidelines when performing a boiler inspection?

Answer 15

Follow safety rules, lock out valves, notify operators, test for oxygen levels, and never inspect alone.

Question 16

What is the general rule regarding pressure testing against instrumentation?

Answer 16

Never pressure test against instrumentation.

Question 17

What should be done with the pressure vessel interior after inspection?

Answer 17

Flush out with a high pressure hose.

Question 18

What can scale formation in firetube boilers lead to?

Answer 18

Overheating of boiler metal, tube failures, and costly repairs.

Question 19

What is the importance of monitoring combustion analysis in relation to scale formation?

Answer 19

Stack temperatures will be elevated due to reduced heat transfer.

Question 20

What should be done if deposits are not fully removed by flushing?

Answer 20

Consult with the boiler manufacturer’s authorized representative.

Question 21

Fill in the blank: An ongoing water treatment program should be set up with a _______.

Answer 21

boiler water treatment specialist.

Question 22

What is required for internal inspections of vessels?

Answer 22

Confined space entry and isolation requirements.

Question 23

What tools should be taken during an internal waterside inspection?

Answer 23

Working flashlight, camera, and scraping tool.

Question 24

True or False: It is acceptable to enter a boiler with a high voltage light.

Answer 24

False. Never enter a boiler with a high voltage light.

Question 25

What should be done if the internal inspection is made at the request of an authorized inspector?

Answer 25

Ask the inspector to observe conditions prior to cleaning.

Question 26

What is a sign of leaking tubes in a boiler?

Answer 26

Excessive water on the fireside.

Question 27

What is the impact of scale formation in boilers?

Answer 27

Scale formation will reduce heat transfer and result in elevated stack temperatures. ## Footnote This can affect combustion analysis.

Question 28

What should be done to the pressure vessel interior after an inspection?

Answer 28

Flush out with a high pressure hose. ## Footnote If deposits remain, consult with the boiler manufacturer's representative.

Question 29

When is acid cleaning required for boilers?

Answer 29

In extreme cases when deposits are not removed by flushing. ## Footnote Professional advice is recommended for acid cleaning.

Question 30

What can extreme scale build-up in a water tube boiler affect?

Answer 30

It will impede water flow through the heat exchanger. ## Footnote This is particularly problematic for coil tube designs.

Question 31

What should be monitored during boiler inspections?

Answer 31

Take pictures and make notes on the current inspection. ## Footnote Compare observations to previous inspections.

Question 32

What should be checked at the point of chemical feed?

Answer 32

Ensure good distribution through the boiler before it contacts the blowdown pipe.

Question 33

What should be inspected in continuous blowdown piping?

Answer 33

Look for corrosion or plugging.

Question 34

What does a broad band water line indicate?

Answer 34

An unstable water level.

Question 35

What are signs of oxygen corrosion in boilers?

Answer 35

Well-defined pits or a very pockmarked surface with reddish-brown oxide caps. ## Footnote Active pits expose black iron oxide or shiny metal when the cap is removed.

Question 36

What should be checked regarding sludge in boilers?

Answer 36

Excessive sludge deposits could indicate hard water intrusion or insufficient bottom blowdown.

Question 37

What is the purpose of removing plugs from low water cut-off piping?

Answer 37

To visually inspect the piping and clean or replace as required.

Question 38

What indicates a need for increased frequency of column blowdowns?

Answer 38

The power engineer must increase frequency if sludge or scale is present.

Question 39

What should be done to check for burner/combustion issues?

Answer 39

Look for signs like flame impingement and soot deposits.

Question 40

How can soot be cleaned from firetube boiler tubes?

Answer 40

Using specialty tools that feed a steel fish tape with an attached brush while a vacuum extracts soot.

Question 41

What maintenance is required for boilers firing digester gas?

Answer 41

Wash off the white coating on the fireside of the tubes periodically to maintain heat transfer.

Question 42

What should be checked regarding baffles and shelves?

Answer 42

Inspect welds for cracks caused by vibration.

Question 43

What should be done after cleaning the waterside of a boiler?

Answer 43

Replace all waterside handhole and manhole gaskets.

Question 44

What should not be applied to handhole or manhole gasket surfaces?

Answer 44

Any sealant like silicone.

Question 45

What is the time-sensitive aspect of safety valves?

Answer 45

The valve serviced date must be monitored to avoid storing serviced valves too long.

Question 46

What should be done when performing a pop test on safety valves?

Answer 46

Raise the operating pressure to the set pressure to allow it to open and reseat.

Question 47

What can frequent use of safety valves cause?

Answer 47

Leakage due to wear on the seat and disc.

Question 48

What must be done for safety valve repairs?

Answer 48

Only the manufacturer or authorized representative should perform repairs.

Question 49

What should be monitored on feed pumps and blowers?

Answer 49

Check the amp draw for signs of bearing deterioration.

Question 50

What are the two methods of boiler storage?

Answer 50

Wet layup and dry layup.

Question 51

What is required for wet layup of a boiler?

Answer 51

The boiler must be flooded with chemically treated water to prevent air separation.

Question 52

What is the purpose of dry layup?

Answer 52

To allow complete drying of the boiler by draining and promoting air circulation.

Question 53

What is wet layup in boiler maintenance?

Answer 53

The boiler must be flooded so there is no water/air separation line in the vessel. The water is chemically treated with corrosion inhibitors. ## Footnote Wet layup helps prevent corrosion during short-term storage.

Question 54

What is dry layup in boiler maintenance?

Answer 54

The boiler is completely drained with all hand hole and man hole covers removed. Air circulation is promoted in the waterside to completely dry out. This is best for long-term storage. ## Footnote Dry layup minimizes the risk of corrosion over extended periods.

Question 55

True or False: In wet layup, the boiler must be completely drained.

Answer 55

False ## Footnote In wet layup, the boiler must be flooded with treated water.

Question 56

Fill in the blank: In dry layup, the boiler is completely _______.

Answer 56

drained ## Footnote This process removes all water to prevent corrosion.

Question 57

What chemical treatment is used in wet layup?

Answer 57

Corrosion inhibitors ## Footnote These inhibitors are essential to protect the boiler from corrosion while in storage.

Question 58

What is promoted in the waterside during dry layup?

Answer 58

Air circulation ## Footnote Air circulation helps ensure that the boiler completely dries out.