Boiler Plant Operation and Management

Question 1

When locking out a cooled down steam boiler
Select one:
a. close the water column and gauge glass valves, and lock them.
b. close the non-return valve drain, and lock it.
c. open the drum vent, and lock or tag it.
d. open the continuous blowdown valve and tag it.

Answer 1

c. open the drum vent, and lock or tag it.

Question 2

When a combustion air opening is equipped with dampers, the dampers must be

Select one:

a. interlocked with the burner, and fully open before starting the boiler.
b. interlocked with the burner, and fully closed before starting the boiler.
c. manually closed, to prevent cold air from entering the boiler room
d. partially open, so the burner is not supplied with too much air on start-up.

Answer 2

a. interlocked with the burner, and fully open before starting the boiler.

Question 3

Which of the following may cause water hammer in steam lines?

Select one:

a. opening steam valves slowly.
b. opening the steam trap bypass valves.
c. having too many condensate drains open.
d. missing or damaged pipe insulation.

Answer 3

d. missing or damaged pipe insulation.

Question 4

R4B04-03-03-07 Failure to \_\_\_\_\_ the furnace thoroughly before light-up can cause a furnace explosion.
Select one:
a. preheat
b. soot-blow
c. cool
d. purge

Answer 4

d. purge

Question 5

Which of the following is NOT done when preparing a steam boiler feedwater system?

Select one:

a. Confirm that the boiler water level is within range.
b. Verify that the boiler feedwater pumps are in service.
c. Open the feedwater control bypass valve.
d. Place the feedwater pre-treatment equipment in service.

Answer 5

c. Open the feedwater control bypass valve.

Question 6

In the case of a single boiler steam heating system, ASME VI advises operators to warm up heating boilers and their steam piping

Select one:

a. quickly.
b. simultaneously.
c. alternately.
d. sequentially.

Answer 6

b. simultaneously.

Question 7

For a wet layup, what is the recommended boiler water sodium sulfite residual?

Select one:

a. 40 ppm
b. 10 ppm
c. 200 ppm
d. 50 to 80 ppm

Answer 7

c. 200 ppm

Question 8

One way to keep oxygen out of the boiler water system is to:
Select one:
a. Increase the continuous blowdown to remove water with high dissolved oxygen concentration.
b. Keep make-up water to a minimum.
c. Keep the drum vent closed when the boiler is not in operation.
d. Control the boiler water pH.

Answer 8

b. Keep make-up water to a minimum.

Question 9

A boiler furnace pre-purge:
Select one:
a. happens after the ignition transformer is energized.
b. can occur even if the boiler has a low water condition.
c. happens only when the draft fans are at low speed.
d. must last a specific amount of time.

Answer 9

d. must last a specific amount of time.

Question 10

Who can remove the supervisory lock from the lock box?

Select one:

a. The plant Workplace Safety and Health committee member.
b. The last contractor working on the boiler.
c. Only the qualified operator who initially performed the lockout.
d. The chief engineer, shift engineer, or qualified person delegated by the chief engineer

Answer 10

d. The chief engineer, shift engineer, or qualified person delegated by the chief engineer.

Question 11

A boiler pressure explosion is NOT caused by:
Select one:
a. Scale and sludge build-up
b. Overheating
c. Insufficient combustion air 
d. Thermal shock

Answer 11

c. Insufficient combustion air

Question 12

A boiler pressure explosion:
Select one:
a. Could be the result of water in the fuel oil
b. Could be the result of inadequate ignition
c. May be caused by a low water condition
d. Could result from a defective flame scanner

Answer 12

c. May be caused by a low water condition

Question 13

How often should operator rounds be performed?

Select one:

a. 1 to 3 times per shift
b. once a week
c. every hour
d. every day

Answer 13

a. 1 to 3 times per shift

Question 14

While warming up and cutting-in a hot water heating boiler with a hot system, which of the following is true?
Select one:
a. Keep the stop valves in the supply and return lines to the boiler closed during warm-up.
b. While warming up, the boiler must be on “high fire” or “automatic.”
c. Close the valves connecting the expansion tank to the on-line boilers, and open the valve that connects the cold boiler to the expansion tank.
d. Make sure the burner shuts off before the safety valve opens.

Answer 14

a. Keep the stop valves in the supply and return lines to the boiler closed during warm-up.

Question 15

The purpose of a boiler boil out is to:
Select one:
a. remove grease and oil from the heat transfer surfaces.
b. determine the level at which the low water cut-off functions.
c. dry out the refractory.
d. clean the fireside surfaces.

Answer 15

a. remove grease and oil from the heat transfer surfaces.

Question 16

To confirm a hot water heating system is full,

Select one:

a. the altitude shown on the tridicator gauge must exceed the pressure indication.
b. the expansion tank level must be at 1/2 a glass.
c. the system pressure must be the same at every elevation.
d. the pressure shown on the tridicator gauge must exceed the altitude indication.

Answer 16

d. the pressure shown on the tridicator gauge must exceed the altitude indication.

Question 17

To help operators keep track of what step they are at in a procedure, the ___________ method is often used.

Select one:

a. Buddy
b. Call-in
c. Simplified Startup
d. Circle/Slash

Answer 17

d. Circle/Slash

Question 18

When warming up a steam boiler, open the boiler drum vent to

Select one:

a. keep a vacuum from forming in the drum, if the burner trips off.
b. permit the release of corrosive dissolved gases, such as oxygen and carbon dioxide, from the boiler water.
c. ensure a flow of steam through the superheater banks.
d. prevent over-pressurization of the boiler during start-up.

Answer 18

b. permit the release of corrosive dissolved gases, such as oxygen and carbon dioxide, from the boiler water.

Question 19

Which of the following is NOT an important reason to take plant readings?

Select one:

a. To compare current field conditions with the expected performance of the equipment.
b. To identify operating trends.
c. To diagnose problems with equipment or processes.
d. To keep operators from becoming complacent.

Answer 19

d. To keep operators from becoming complacent.

Question 20

“SOP” stands for

Select one:

a. Simplified Operating Procedure
b. Standard Operating Procedure
c. Simplified Operating Practices
d. Special Operating Procedure

Answer 20

b. Standard Operating Procedure

Question 21

CSD-1 recommends that flame rods and scanners be replaced

Select one:

a. monthly
b. annually
c. after 5000 hours of operation
d. before problems occur.

Answer 21

b. annually

Question 22

In the event of a power failure, which of the following will likely require a manual restart when power is restored?

Select one:

a. air dryers
b. small condensate return pumps
c. unit heater fans
d. large air compressors

Answer 22

d. large air compressors

Question 23

How often should the desiccant be checked during a dry layup?

Select one:

a. Semi-annually.
b. Annually.
c. Daily.
d. Bi-weekly to monthly.

Answer 23

d. Bi-weekly to monthly.

Question 24

On a boiler fuel system that has a “double block and bleed” arrangement:
Select one:
a. The ”bleed” valve is a normally open solenoid valve.
b. The main SSOVs energize when the bleed valve de-energizes.
c. The main SSOVs open before the pre-purge occurs
d. The main SSOVs and the vent valves open at the same time.

Answer 24

a. The ”bleed” valve is a normally open solenoid valve.

Question 25

Rising stack temperatures, at a given firing rate, indicate Select one: a. Correct burner operation b. A defective stack thermometer c. Boiler corrosion d. heat transfer surfaces are becoming dirty.

Answer 25

d. heat transfer surfaces are becoming dirty.

Question 26

Larger capacity, high pressure fuel trains are Select one: a. simpler b. more complex c. safer d. more efficient

Answer 26

b. more complex

Question 27

How should the operating limit pressure control switch on a steam boiler be tested? Select one: a. Observe that the boiler cuts in and cuts out during routine boiler operation. b. Jumper the contacts and observe when the boiler shuts off c. Install a new control annually, because the operating limit cannot be easily tested. d. Remove the control from the boiler and test with a pressure source and a master pressure gauge.

Answer 27

a. Observe that the boiler cuts in and cuts out during routine boiler operation.

Question 28

The most important rule in safe operation of steam boilers is to: Select one: a. keep the heat transfer surfaces clean. b. maintain the boiler room log c. try to keep make-up water to a minimum. d. keep water in the boiler at the proper level.

Answer 28

d. keep water in the boiler at the proper level.

Question 29

ASME VII states that a high-pressure steam plant comprised of a single power boiler may have its boiler and steam lines Select one: a. interconnected with two other boilers. b. warmed-up at the same time, or independent of each other. c. made of cast iron. d. drained by the same steam trap

Answer 29

b. warmed-up at the same time, or independent of each other.

Question 30

A slow drain test is performed to Select one: a. check the operation of a low water cut-off b. check the operation of the blowoff tank and quenching water system c. check the operation of a feedwater control valve d. check the blowoff valves and blowoff line for obstruction

Answer 30

a. check the operation of a low water cut-off

Question 31

How often should a LWCO float chamber blowdown test be performed on a power boiler? Select one: a. monthly. b. annually. c. weekly. d. daily.

Answer 31

d. daily.

Question 32

Which is the first step when starting a boiler's fuel oil system? Select one: a. Start the fuel pump. b. Reset the low oil pressure cut-off switch. c. Check the pressure drop across the fuel filter. d. Check for leaks.

Answer 32

a. Start the fuel pump.

Question 33

A typical natural gas flame should be Select one: a. bright yellow, with black tips. b. bright yellow, with orange tips. c. blue, with orange at the tip of the flame d. asymmetrical, and as close as possible to the heat transfer surfaces

Answer 33

c. blue, with orange at the tip of the flame

Question 34

Rust in the gauge glass is an indication that: Select one: a. The boiler should be blown off. b. The dissolved solids concentration has peaked. c. The continuous blowdown setting needs to be increased. d. Corrosion is occurring in the system

Answer 34

d. Corrosion is occurring in the system

Question 35

New boilers require a _____________ and a _____________ dry-out before entering operation. Select one: a. mechanical cleaning, fireside b. certificate, complete c. refractory curing, waterside d. boil-out, refractory

Answer 35

d. boil-out, refractory

Question 36

What is the recommended boiler water pH for wet layup? Select one: a. 7.5 b. 7 c. 12 d. 10

Answer 36

d. 10

Question 37

Slight smoking when first starting a cold oil-fired boiler Select one: a. is caused by too much excess air. b. is caused by too little fuel pressure. c. is abnormal, and requires immediate attention. d. occurs because the furnace is cold

Answer 37

d. occurs because the furnace is cold.

Question 38

As part of a preventative maintenance schedule, duty swaps: Select one: a. distribute wear between regular and standby equipment. b. are seldom performed on boiler feed pumps. c. involve starting a piece of equipment to record performance data, and then shutting it down again. d. are performed when another piece of equipment breaks down.

Answer 38

a. distribute wear between regular and standby equipment.

Question 39

If a steam boiler is in service and no water level shows in the gauge glass, the first action would be to: Select one: a. operate the bottom blowoff valves. b. shut off the fuel and air to the furnace c. start the standby feed pump d. determine whether the gauge glass is completely full or completely empty.

Answer 39

d. determine whether the gauge glass is completely full or completely empty.

Question 40

The main burner test firing valve should be opened Select one: a. when testing the high gas pressure cut-off b. during a flame-out c. when taking a fuel sample d. before starting the main burner

Answer 40

d. before starting the main burner

Question 41

Although boilers have many different ignition systems, they all follow the same sequence of steps. Which of the following is the third step? Select one: a. Post Purge b. Pilot ignition c. Pre-purge d. Main burner ignition

Answer 41

d. Main burner ignition

Question 42

Standby equipment: Select one: a. should never run unless required. b. require little or no maintenance. c. need annual run tests, witnessed by an authorized inspector. d. should be run on a regular basis.

Answer 42

d. should be run on a regular basis.

Question 43

The safety valve of a steam heating boiler pops open at 100 kPa. Which of the following is a code-acceptable re-seating pressure? Select one: a. 98 kPa b. 50 kPa c. 80 kPa d. 65 kPa

Answer 43

c. 80 kPa

Question 44

``` How often should the low water cut-off of a low pressure steam heating boiler be blown off? Select one: a. Daily b. Monthly c. Twice per shift d. Weekly ```

Answer 44

a. Daily

Question 45

A fast-closing valve that automatically and completely shuts off the fuel supply, in response to an operating limit or a safety limit, is a Select one: a. firing rate control valve b. schrader valve c. safety shut-off valve d. test firing valve

Answer 45

c. safety shut-off valve

Question 46

A power boiler in steam service has a safety valve set to 2000 kPa. What should the maximum operating pressure be for this boiler? Select one: a. 1800 kPa. b. 1990 kPa. c. 1950 kPa. d. 2000 kPa.

Answer 46

a. 1800 kPa

Question 47

Which code contains information on safety valves for high pressure steam boilers? Select one: a. ASME Section I b. ASME Section IV c. ASME B31.5 d. CSA B-52

Answer 47

a. ASME Section I

Question 48

Prior to shutting down a hot water boiler for an extended shutdown: Select one: a. Raise the pressure to test the safety relief valve. b. Shut the boiler off when firing on high by closing the main test firing valve. c. Test all operating and limit controls. d. Start draining the boiler slowly.

Answer 48

c. Test all operating and limit controls.

Question 49

On a semi-automatic ignition system, the switch on the supervised cock Select one: a. keeps the boiler from pre-purging if the pilot test firing valve is open. b. allows the boiler to automatically recycle. c. keeps the boiler from pre-purging if the main test firing valve is open. d. shuts down the boiler if the main test firing valve is opened during operation.

Answer 49

d. shuts down the boiler if the main test firing valve is opened during operation.

Question 50

Which of the following is a desiccant used for dry layup? Select one: a. Quick lime b. Silicone Gel c. Lime soda d. Soda ash

Answer 50

a. Quick lime

Question 51

If the safety relief valve of a hot water heating boiler is set to open at 207 kPa, the operating pressure should not exceed Select one: a. 207 kPa. b. 52 kPa. c. 138 kPa. d. 155 kPa.

Answer 51

c. 138 kPa.

Question 52

Water hammer can be caused by operators: Select one: a. draining condensate prior to heating up steam lines. b. opening valves too quickly. c. starting a pump with the discharge valve closed. d. opening valves too slowly.

Answer 52

b. opening valves too quickly.

Question 53

What should Power Engineers carry at all times? Select one: a. spare fuses b. a small wrench c. a flashlight d. a cell phone

Answer 53

c. a flashlight

Question 54

``` If a cold boiler is warmed up slowly Select one: a. it cannot over-pressurize b. it will develop less stress due to uneven thermal expansion. c. the refractory may overheat. d. condensation will not occur. ```

Answer 54

b. it will develop less stress due to uneven thermal expansion.

Question 55

If the water level in the boiler gauge glass cannot be seen, the first thing to do is: Select one: a. Open the gauge glass drain to determine whether the glass is full or empty. b. Start the standby feedwater pump. c. Shut off the fuel supply to the boiler. d. Blow off the boiler. e. Ensure the glass is not leaking

Answer 55

a. Open the gauge glass drain to determine whether the glass is full or empty

Question 56

If a power failure occurs, which of the following valves fail open? Select one: a. Main fuel safety shut-off valve. b. Boiler feedwater valve. c. Fuel line bleed valve. d. Pilot fuel safety shut-off valve.

Answer 56

c. Fuel line bleed valve.

Question 57

Before performing a try lever test on a power boiler, what pressure should the boiler be at? Select one: a. the set pressure of the safety valve b. the boiler MAWP c. at or above 750 kPa d. at least 75% of the set pressure of the safety valve

Answer 57

d. at least 75% of the set pressure of the safety valve

Question 58

Deaerators often have low-level alarms and low-low level trips Select one: a. in case the boiler trips. b. in case the boiler feedwater valve fails open. c. in case the boiler feedwater pumps trip. d. in case the condensate transfer pumps trip

Answer 58

d. in case the condensate transfer pumps trip.

Question 59

``` One cause of main flame failure in oil fired boilers is: Select one: a. Excessive fuel temperature. b. Excessive purge duration. c. Excessive furnace temperature. d. Water in the fuel ```

Answer 59

d. Water in the fuel

Question 60

A wide and rapid fluctuation of the water level in a boiler gauge glass may be the result of: Select one: a. High dissolved solids concentration in the boiler water b. A vapour bound boiler feed pump c. Low alkalinity d. Low pH

Answer 60

a. High dissolved solids concentration in the boiler water

Question 61

When warming up a boiler, it should be: Select one: a. warmed up quickly so there is not enough time for differential thermal expansion to occur b. warmed up quickly to prevent flue gas condensation c. warmed up at a rate of one degree every five minutes, to protect the refractory d. warmed up at 55 degrees Celsius per hour, to prevent thermal shock

Answer 61

d. warmed up at 55 degrees Celsius per hour, to prevent thermal shock

Question 62

When closing up a boiler, Select one: a. handhole and manhole gaskets must be coated with sealant, such as graphite paste or silicone. b. handhole and manhole gaskets should be reused, because they are expensive. c. handhole and manhole yokes must be torqued until the gaskets are compressed to less than 1 mm thick. d. new handhole and manhole gaskets must be used, to prevent dangerous blowouts and costly unplanned boiler outages.

Answer 62

d. new handhole and manhole gaskets must be used, to prevent dangerous blowouts and costly unplanned boiler outages.

Question 63

A well-planned PM system will Select one: a. create less need for rounds and inspections. b. ensure equipment longevity. c. will cover only the most critical plant equipment. d. respond quickly to equipment breakdown.

Answer 63

b. ensure equipment longevity.

Question 64

Which of the following is NOT a way to maintain a positive pressure on a boiler during a wet layup? Select one: a. use a head tank. b. use an oxygen scavenger. c. use a nitrogen blanket. d. use a steam blanket.

Answer 64

b. use an oxygen scavenger.

Question 65

When a power failure occurs, control valves Select one: a. fail shut. b. go to a fail-safe position. c. fail last. d. fail open.

Answer 65

b. go to a fail-safe position

Question 66

When should wet layup be used? Select one: a. For long term storage. b. When a boiler may be exposed to freezing conditions. c. When a boiler is on standby. d. When desiccant is unavailable.

Answer 66

c. When a boiler is on standby.

Question 67

New refractory in a boiler must be thoroughly dried on low fire Select one: a. because high fire uses too much fuel. b. by operating only the pilot burner. c. for no longer than one hour. d. to dry the refractory slowly and keep it from cracking.

Answer 67

d. to dry the refractory slowly and keep it from cracking.

Question 68

If the main burner goes out when warming up a cold boiler, the operator should immediately: Select one: a. turn off the boiler, purge the furnace, and restart the burner b. shut down the boiler, close the main and pilot test firing valves, and determine the cause of the trouble. c. re-light the burner to see if it goes out again. d. report the flame failure to the Chief Engineer.

Answer 68

b. shut down the boiler, close the main and pilot test firing valves, and determine the cause of the trouble.

Question 69

In a multiple boiler high pressure steam plant, when starting an entire system from cold Select one: a. The entire system warms and pressurizes as one boiler warms, except for the boilers being left off line. b. A small auxiliary heating boiler is used to warm the steam lines while the power boilers are warming. c. All the boilers are started and warmed at the same time. d. Boilers remaining off-line must have their boiler and header stop valves open, and their non-return drain valves shut.

Answer 69

a. The entire system warms and pressurizes as one boiler warms, except for the boilers being left off line.

Question 70

To prevent water hammer and the severe damage it causes, it is imperative that Select one: a. steam lines and headers are warmed up before admitting steam to the steam lines. b. steam traps are isolated during warm up. c. boilers are warmed slowly. d. steam lines and headers are isolated before boilers are started.

Answer 70

a. steam lines and headers are warmed up before admitting steam to the steam lines.

Question 71

If a boiler sustains a low water condition Select one: a. use cool feedwater to quench any overheated heating surface. b. shut down the burner, let the boiler cool slowly, then drain and inspect it for damage due to overheating. c. immediately feed water into the boiler to raise the level. d. open the safety valve or drum vent valve to release pressure.

Answer 71

b. shut down the burner, let the boiler cool slowly, then drain and inspect it for damage due to overheating.

Question 72

Furnace explosions may be caused by: Select one: a. Inoperative low water fuel cut-offs b. The accumulation of fuel-air mixture in the furnace c. Scale accumulations on the boiler surfaces d. Excessive furnace purging

Answer 72

b. The accumulation of fuel-air mixture in the furnace

Question 73

Because natural gas is colourless and odourless, ___________ is added to the gas so that it is easier to detect a leak. Select one: a. mercaptan b. propane c. fluorescent dye d. an irritant

Answer 73

a. mercaptan

Question 74

Boilers should be warmed up Select one: a. with maximum combustion air, to prevent smoking b. rapidly, so the metal heats up faster c. slowly, to minimize differential expansion and thermal shock d. using only the pilot burner.

Answer 74

c. slowly, to minimize differential expansion and thermal shock

Question 75

A high water level in a boiler: Select one: a. Will cause the high water cut-off to shut down the boiler b. Is usually caused by a boiler feed pump malfunction c. Will necessitate an immediate shutdown and cool down d. May cause water carryover into the header

Answer 75

d. May cause water carryover into the header

Question 76

Mechanical chart recorders Select one: a. require constant winding of their clock mechanisms. b. are used so regular readings do not need to be taken. c. need their charts replaced each month. d. require regular replacement of paper and ink.

Answer 76

d. require regular replacement of paper and ink.

Question 77

If a new boiler is not boiled out correctly, the result may be: Select one: a. Refractory damage b. Excessive waterside corrosion c. Excessively high water circulation rates d. Foaming

Answer 77

d. Foaming

Question 78

Regarding maintenance programs, what does "PM" stand for? Select one: a. Preventative Maintenance b. Planned Maintenance c. Periodic Maintenance d. Plant Maintenance

Answer 78

a. Preventative Maintenance

Question 79

``` A boiler boil-out Select one: a. is done with an alkaline solution. b. must be done annually. c. is done before curing the refractory. d. is done at 1.5 times the maximum allowable working pressure ```

Answer 79

a. is done with an alkaline solution.

Question 80

What is usually considered the first task when coming onto a shift: Select one: a. complete the water tests b. Check water levels c. perform a complete set of operator rounds d. read the log book

Answer 80

d. read the log book

Question 81

In many plants, the standby boiler feedwater pump starts automatically when Select one: a. the feedwater control valve opens greater than 95%. b. the water level reaches the lowest permissible water level. c. a low water alarm occurs. d. the on-line pump fails to provide adequate feedwater pressure.

Answer 81

d. the on-line pump fails to provide adequate feedwater pressure.

Question 82

Who should verify a steam boiler lockout? Select one: a. Nobody. b. A second qualified operator. c. A representative of the plant Workplace Safety and Health committee. d. Each and every contractor or employee working on the boiler.

Answer 82

b. A second qualified operator.

Question 83

What is the recommended test frequency for flame safeguard devices? Select one: a. weekly b. annually c. every shift d. daily

Answer 83

a. weekly

Question 84

The procedure for cutting a power boiler into a pressurized steam header is described in Select one: a. ASME Section VII. b. CSA B51. c. ASME Section I. d. ASME Section IV.

Answer 84

a. ASME Section VII.