Book 1: 3-12 "Routine Boiler Maintenance & Inspection"

Question 1

Chemicals used for the alkaline boil out of a boiler consist of a combination of which of the following.
1. Sodium hydroxide
2. Sodium sulphite
3. Sodium phosphate
4. Sodium carbonate
5. Sodium chloride
Select one:

A. 2, 3, 4

B. 2, 3, 4

C. 1, 2, 3

D. 1, 3, 4

E. 1, 2, 4

Answer 1

D. 1, 3, 4
(Sodium hydroxide, Sodium phosphate, Sodium carbonate)

Question 2

The boiler inhibited acid cleaning method most commonly uses a 5% solution of inhibited _____ acid.
Select one:

A. Nitric

B. Sulphuric

C. Hydrochloric

D. Carbonic

E. Acetic

Answer 2

C. Hydrochloric

Question 3

The dye penetrant, entrapped in a crack, is brought to the surface by the action of the:
Select one:

A. Black light

B. Dye penetrant

C. Ultrasound

D. Ultraviolet light

E. Developer

Answer 3

E. Developer

Question 4

In the case of a firetube boiler, the scale will be formed on the outside surfaces of the tubes and may be removed by passing a _____ through the tubes.
Select one:

A. Tube cleaner

B. Disc grinder

C. Scale cutter

D. Wire brush

E. Vibrating hammer or “rattler”

Answer 4

E. Vibrating hammer or “rattler”

Question 5

When the boiler water has cooled to about _____ open the blowdown valves and drain the boiler.
Select one:

A. 99°C (210°F)

B. 134°C (273°F)

C. 90°C (194°F)

D. 110°C (230°F)

E. 60°C (140°F)

Answer 5

C. 90°C (194°F)

Question 6

Whenever there are signs of a tube leak during boiler operation:
Select one:

A. Reduce the firing rate to the minimum

B. Watch that it does not get worse

C. Close the stop valve on the steam outlet

D. Shut down the boiler immediately

E. Maintain a steady firing rate

Answer 6

D. Shut down the boiler immediately

Question 7

Tubes adjacent to sootblowers are examined for signs of _____ due to direct impingement of steam from the blowers.
Select one:

A. Erosion

B. Overheating

C. Oxygen pitting

D. Corrosion

E. Caustic embrittlement

Answer 7

A. Erosion

Question 8

Tubes and tube sheets should be inspected for scale formation and:
Select one:

A. Trueness

B. Erosion

C. Pitting

D. Corrosion

E. Alignment

Answer 8

C. Pitting

Question 9

When inspecting the fireside of the boiler the surfaces are examined for bulges or blisters which would indicate:
Select one:

A. Corrosion

B. Oxygen pitting

C. Overheating

D. Erosion

E. Caustic embrittlement

Answer 9

C. Overheating

Question 10

Standard antifriction bearings normally require lubrication once every _____ year/s.
Select one:

A. 5

B. 1

C. 2

D. 4

E. 3

Answer 10

B. 1

Question 11

Overheating of the tube wall may be caused by all but:
Select one:

A. Low excess air

B. Heavy scale forming on the tubes

C. Failure of the low water fuel cut-off

D. An excessive firing rate

E. Poor water circulation

Answer 11

A. Low excess air

Question 12

Black light is the popular name for invisible light in the near _____ range of wave lengths.
Select one:

A. Green light

B. Infrared

C. Ultraviolet

D. Violet light

E. Ultrasonic

Answer 12

C. Ultraviolet

Question 13

In the wet boiler lay up method after the boiler water has cooled it is filled:
Select one:

A. To half a gauge glass

B. To the bottom of the gauge glass

C. To the top of the gauge glass

D. To half fill the boiler

E. Completely

Answer 13

E. Completely

Question 14

Although cast iron is a _____ material that cracks relatively easily, it has proven to be a satisfactory material for low-pressure boilers.
Select one:

A. Strong

B. Malleable

C. Brittle

D. Ductile

E. Fragile

Answer 14

C. Brittle

Question 15

Sealed antifriction bearings usually don’t require additional lubrication for a period of _____ years.
Select one:

A. 1

B. 5

C. 3

D. 4

E. 2

Answer 15

C. 3

Question 16

Repairs affecting the pressure parts of a boiler may only be made after consultation with and the approval of:
Select one:

A. The Chief Engineer

B. The authorized inspector

C. A qualified welder

D. The Shift Engineer

E. A Professional Engineer

Answer 16

B. The authorized inspector

Question 17

During inhibited acid cleaning the boiler must be adequately vented because _____ is produced by the reaction of acid with iron and could cause a fire or explosion.
Select one:

A. Hydrogen

B. Nitrogen

C. Carbon dioxide

D. Oxygen

E. Carbon monoxide

Answer 17

A. Hydrogen

Question 18

If damp conditions exist during the idle season, the metal surfaces should be painted with a protective coating such as:
Select one:

A. Fuel oil

B. Grease

C. Light oil

D. Oil based paint

E. Latex paint

Answer 18

C. Light oil

Question 19

In the wet boiler lay up method chemicals are added to bring the boiler water to the required:
Select one:

A. TDS

B. pH

C. Excess oxygen scavenger level

D. Acidity

E. Density

Answer 19

C. Excess oxygen scavenger level

Question 20

Hydrostatic testing of a boiler requires that the pressure be raised to _____ the Maximum Allowable Working Pressure stamped on the boiler.
Select one:

A. 1.5 times

B. 2.0 times

C. 1.0 times

D. 0.5 times

E. 1.25 times

Answer 20

A. 1.5 times

Question 21

Power Engineers (boiler operators) are generally not called upon to make any boiler repairs they are usually done by an experienced:
Select one:

A. Plumber

B. Steam fitter

C. Boilermaker

D. Millwright

E. Carpenter

Answer 21

C. Boilermaker

Question 22

After cleaning, cast-iron boilers should be left completely filled with _____ in order to reduce corrosion.
Select one:

A. A slightly basic solution

B. A mixture of oil and antifreeze

C. Light oil

D. A slightly acidic solution

E. Water

Answer 22

E. Water

Question 23

In the circulating method, the acid solution is circulated continuously through the unit at a temperature of about _____ until the cleaning action is completed as shown by tests.
Select one:

A. 120°C (248°F)

B. 50°C (98°F)

C. 100°C (212°F)

D. 65°C (150°F)

E. 77°C (170°F)

Answer 23

D. 65°C (150°F)

Question 24

Leakage of a few drops a minute leakage from the packing gland of circulating pumps is desirable to prevent drying out of packing and:
Select one:

A. Over cooling of the shaft

B. Corrosion of the shaft

C. Prevent ingress of air

D. Scoring of the shaft

E. Creating to large a mess

Answer 24

D. Scoring of the shaft

Question 25

One of the main purposes of the external boiler inspection is to:
Select one:

A. Check for misalignment

B. Watch for settling

C. Observe operation and maintenance practices

D. Check for boiler leaks

E. Watch for hot spots

Answer 25

C. Observe operation and maintenance practices

Question 26

Portable lamps of _____ or less, with current supplied from transformers or batteries, should be provided to eliminate the danger of electrocution to personnel inside the boiler.
Select one:

A. 1.5 V

B. 12 V

C. 32 V

D. 24 V

E. 110 V

Answer 26

B. 12 V

Question 27

The boiler firebox, gas passages and chimney should be thoroughly cleaned by wire brushing and:
Select one:

A. Scrubbing

B. Vacuuming

C. Sand blasting

D. Painting

E. Oiling

Answer 27

B. Vacuuming

Question 28

A complete check of the boiler heating system should be carried out:
Select one:

A. Some time during the next heating season

B. At the start of the next heating season

C. Some time over the summer

D. At the convenience of the Chief Engineer

E. At the end of the heating season

Answer 28

E. At the end of the heating season

Question 29

It is unlawful to have any welder other than the holder of a Pressure Welder Certificate and a valid _____ do any welding on any pressure part of the boiler.
Select one:

A. First aid certificate

B. Quality assurance card

C. “B” pressure ticket

D. Performance Qualification Card

E. Union card

Answer 29

D. Performance Qualification Card

Question 30

Flame retarders can be found in the boiler:
Select one:

A. Mud drum

B. Shell

C. Water tubes

D. Steam drum

E. Fire tubes

Answer 30

E. Fire tubes