Principles of Operation for an Auxiliary Boiler Flashcards
1
Q
A boiler is a container used to produce WHAT?
A
Steam or hot Water
2
Q
The function of auxiliary boilers is to supply steam or hot water for the following applications:
A
- Heating Systems
- Galley Equipment
- Evaporators
- Laundry Rooms
- Water Heaters
3
Q
Name three things needed to produce steam or hot water.
A
- Water
- Heat (produced by an oil burner)
- Container to hold water & steam (boiler)
4
Q
There are two types of Auxiliary Boilers:
A
- Firetube boilers
- Watertube boilers
5
Q
Operating auxiliary boilers includes doing the following:
A
- Prelight-off Checks
- Lighting Off
- Monitoring
- Securing the boiler
6
Q
Before attemping to light off any boiler, become familiar with the Unit’s Operating Procedures and The ___________.
A
Manufacturer’s Operating Manuals
7
Q
Advantages of a Firetube Boiler are:
A
- Inexpensive to build
- Simple to operate
- Less maintenance
8
Q
Dis advantages of a firetube boiler are:
A
- Long warm-up time
- Weight of unit compared to the amount of steam produced
9
Q
The advantages of a Watertube Boiler are:
A
- Less warm-up time
- Ratio of size and weight to steam produced
10
Q
Dis advantages of a Watertube Boiler are:
A
- Requires more maintenance
- Expensive to build
11
Q
Steam results when sufficient heat is added to water which causes it to?
A
Vaporize (boil)
12
Q
The temperature at which water boils is called the?
A
Boiling Point or Saturation Point
13
Q
Notice that the pressure and saturation temperature are driectly proportional. This relationship is called?
A
A Pressure/Temperature Relationship
14
Q
Two types of heat are:
A
- Sensible Heat
- Latent (hidden) Heat
15
Q
Heat is applied to room temperature water. The temperature of the water rises. This is called?
A
Sensible Heat
Sensible Heat causes a change in temperature
16
Q
- Causes a change in state
- Does not cause a change in temperature
A
Latent Heat
The temperature remains constant until the water has vaporized.
17
Q
Two types of Latent Heat:
A
- Vaporization
- Condensation
18
Q
Heat is added to make steam or?
A
“Latent Heat of Vaporization”
19
Q
Remove heat from steam and the steam changes from gas to liquid. This heat is termed?
A
“Latent Heat of Condensation”
20
Q
After the last drop of water is vaporized and heat is continued to be added, the temperature of the steam begins to rise again. Again a complete change of state has taken place and the heat is term “sensible heat”.
A
Superheated Steam
21
Q
The steam is said to be ____, because it is at a temperature above it’s Saturation Point.
A
Superheated
22
Q
Steam that is at the temperature and pressure that it was formed is called?
A
Saturated Steam
23
Q
All auxiliary boilers in the CG produce?
A
Saturated Steam
24
Q
Steam which contains 20% moisture is considered?
A
80% quality
25
Steam which contains 50% moisture is considered?
50% quality
26
Steam which contains 70% moisture is considered?
30% quality
27
As the saturated steam gives up its heat, the steam returns back to its liquid state. This liquid is called?
Condensate
28
The source of water for the boiler is called?
Feedwater
29
The condensate tank is filled from the potable water system when there are:
* Leaks
* Blowdowns
* Discharge of steam to the atmosphere
30
The condensate tank is separated from the steam users by the means of a "\_\_\_\_\_".
Steam Trap
31
Allows condensate to flow back to the condensate tank but trap the steam.
Steam Trap
32
Steam Traps that are most commonly used by the CG are?
* Thermostatic Float Type
* Inverted Bucket Type
33
Gauge Pressure PSI 0.0 = Saturation Temperature???
212.0 degrees fahrenheit
34
Gauge Pressure PSI 2.3 = Saturation Temperature???
219.4 degrees fahrenheit
35
Gauge Pressure PSI 30.3 = Saturation Temperature???
274.5 degrees fahrenheit
36
Gauge Pressure PSI 50.3 = Saturation Temperature???
298.0 degrees fahrenheit
37
Gauge Pressure PSI 100,0 = Saturation Temperature???
337.9 degrees fahrenheit
38
Gauge Pressure PSI 145.3 = Saturation Temperature???
353.5 degrees fahrenheit
39
In preparation for troubleshooting the auxiliary boiler, identify:
* System components
* Subsystem effects on the auxiliary boiler
* Equipment operation procedures
* Standard operating procedures
* any potential hazards
40
\_\_\_\_\_\_\_ must be kept clean.
Blower assembly
41
A excessive buildup of dirt and grime causes an inadequate amount of air supply for combustion and results in a \_\_\_\_\_\_\_.
dirty, smokey flame
42
The frequency that blowdowns are performed depends on the boiler water test; however, perform a blowdown at least \_\_\_\_\_\_\_.
every 72 hours
43
The _______ is located at the point on the boiler where the water and the steam meet.
surface blowdown valve
44
\_\_\_\_\_\_\_\_\_ are used to control boiler water chloride and non-detergent lubricating oils and to reduce over teatment of chemicals.
Surface blowdowns
45
Slowly open surface blowdown valve until sufficient blowdown has taken place, approximately \_\_\_\_\_\_\_\_.
20 to 30 seconds
46
The _______ is located at the lowest point on the boiler.
Bottom Blowdown Valve
47
Bottom blowdowns are used to control ______ in the boiler shell.
Sludge
48
The ______ and ______ are relatively maintenance free.
Air Deflector and Nozzle Centering Stabilizer
49
Inspect the combustion diffuser cone anytime fireside maintenance is performed for:
* Soot buildup due to a misfiring nozzle
* Warpage
* Melted cone
50
When the cone is warped or melted, it must be\_\_\_\_\_.
Replaced
51
Three basic adjustments made on all Electrodes include:
* Gap between the tips of the Electrodes
* Height above the top of the nozzle
* Distance from the side or center of the nozzle
52
Soot from the ______ builds up and needs to be cleaned.
Combustions Gases
53
The _______ are cleaned with a wooden pick and approved solvent.
Distibutor and Orfice
54
The screen is cleaned with an \_\_\_\_\_\_\_.
Approved Solvent
55
The fireside is where ______ takes place.
Combustion
56
\_\_\_\_\_\_\_ is a product of combustion and build up on the fireside.
Soot
57
Soot build up must be removed to aviod inefficient boiler operation cause by:
* Restricted airflow through boiler results in back-pressure in the furnace.
* Soot build up on tubes has an insulating effect and blocks heat transfer from hot combustion gases to the water in the boiler
58
DO NOT use wire brush to remove soot from any insulation found in the fireside as damage will occur. Light brushing with a \_\_\_\_\_\_will remove this soot.
Natural Fiber Brush
59
After removal of soot is complete, inspect firesides for any sign of \_\_\_\_\_\_\_\_\_\_.
Wear or water leakage
60
Most fuel pumps used on auxiliary boilers are ______ with an internal bypass regulator.
two-stage internal gear-type pumps
61
A two stage pump contains two sets of gears. One set acts as the suction gears to draw the fuel into the pump. The other set, known as the \_\_\_\_\_\_, delivers the fuel under sufficient pressure to atomize.
Pressure Gears
62
\_\_\_\_\_\_\_\_ pumps contain a single set of gears which perform both functions as the suction and pressure gears on a two-stage pump.
Single-Stage Pumps
63
In addition to the in-line fuel strainers in the supply piping to the fuel pump, there is a pump driven, self cleaning, rotary type of ______ incorporated in the design of the pump itself.
Fuel Filter
64
\_\_\_\_\_\_\_\_ are access plates which may be removed for inspection of internal areas such as the waterside of an auxiliary boiler.
Handhold Covers
65
Monitoring the boiler includes checking:
* Fuel Pressure
* Fuel Pump Suction
* Ignition
* Steam Pressure
* Water levels in boiler and feedwater tank
* Fuel, steam and water leaksDevices
66
Designed to shutdown the burner and prevent flooding of the furnace with fuel in the event of ignition failure or flame failure.
Safety Combustion Controls
67
Two type of Safety Combustion Controls are:
* Photoelectric Eye
* Photoconductive Eye
**_NOTE:_** These types of controls must be kept clean to work properly.
68
Fuel pump inlet pressure should not exceed _____ in order to comply with the National Fire Protection Association's Bulletin 31.
3-psi gauge
69
What is the oil pressure desired set point for Way-Wolff and Johnston Boilers?
* 100 psi for the Way-Wolff Boiler
* 210 psi for the Johnston Boiler
70
Handhold covers provide access for the inspection of the waterside on boilers. Inspect the handhold cover _____ for leaks.
Weekly
71
Leaks allowed to exist for a length of time may\_\_\_\_\_.
"Wire Draw"
72
Remove scale during waterside maintenance by washing with a high pressure water hose at what psi?
50-60 psi
73
What is the adjustment for the Air Damper if you see Black Smoke?
Gradually open damper
74
What is the adjustment for the Air Damper if you see Clear Exhaust?
Properly burning, no adjustment required
75
What is the adjustment for the Air Damper if you see White Smoke?
Gradually close damper, do not close completely
76
When black smoke from an auxiliary boiler is detected and the possible cause is "Improperly adjusted air damper. The remedy is?
Adjust air damper to allow more air (open)
77
When black smoke from an auxiliary boiler is detected and the possible cause is "Deffective Nozzle. The remedy is?
Clean/renew nozzle per manufacture's technical manual
78
When black smoke from an auxiliary boiler is detected and the possible cause is "Defective fuel pump". The remedy is?
Adjust regulator
79
When black smoke from an auxiliary boiler is detected and the possible cause is "Dirty Blower". The remedy is?
Clean blower wheel
80
When black smoke from an auxiliary boiler is detected and the possible cause is "Insufficient air supply". The remedy is?
* Check for proper compartment air pressure
* Check blower inlet for restrictions
81
When a defective alarm will not silence, it indicates a defective \_\_\_\_\_.
Relay
82
When alarm sounds but a light does not illuminate, it indicates a \_\_\_\_\_\_\_.
Defective Light Bulb
83
The ______ is one of the most important components in the oil burner affecting efficient and trouble-free operation.
Nozzle
84
A dirty or faulty nozzle can cause:
* Reduced efficiency
* Incomplete combustion
* Soot accumulation
85
Over a period of time, the lead sulfide detecor's lens becomes dirty and can give\_\_\_\_\_\_\_ of flame failure.
False Indications
86
If the FSC does not reset upon flame failure, the FSC is \_\_\_\_\_\_\_.
Defective
87
the flame scanner monitors ________ generated by the combustion flame.
Infrared Wave Signals
88
The Flame Scanner consist of 3 major components:
* scanner lead and recepticle
* lead sulfide plug-in cell
* optical lens cap
89
Flame Scanner assembly is defective if \_\_\_\_\_\_volts are not present.
15 to 20 volts
90
An increase in the amount of vacuum on the fuel pump suction gauge may be an indication of the \_\_\_\_\_\_.
fuel filter becoming clogged
91
A lower than normal discharge pressure from the fuel pump may indicate a \_\_\_\_\_\_\_.
Faulty fuel pump
92
Surface blowdowns should be done daily or when the total dissolved solids exceed ______ PPM.
1,000 ppm
93
When experiencing high steam pressure check the following:
* Operating pressure control
* High limit pressure control
94
If high water persist, check the ________ and adjust if necessary.
Float-type water cut-out
95
If low steam pressure persist, perform the following procedures:
* Adjust Operative Pressure Control
* Clean Firesides or Watersides
96
Prior to adjusting pressure switches, ensure that a _______ steam pressure gauge is being used.
Calibrated
97
All safety valves of each auxiliary boiler are tested ______ IAW PMS.
Annually
98
Auxiliary boiler safety valves are steam tested on the boiler to determine correct operation at present pressures as follows:
* Annually
* After each hydrostatic test
* After being removed or replaced
* After being accidently lifted by water during hydrostatic testing
99
\_\_\_\_\_\_\_\_ prevents heat transfer and leads to overheating and eventually tube failure.
Sludge
100
After flushing the waterside of the boiler, refill boiler and hydrostatically test to\_\_\_\_\_\_\_\_\_.
75 psi for 15 minutes to check for leaks
101
In the mid-1800's, Michael Faraday, an English physicist and chemist, revealed the phenomenon now known as \_\_\_\_\_\_\_\_\_\_\_\_.
Electromagnetic Induction
102
Magnetic Water Testing eliminates:
* Scale
* Discharge of treatment chemicals to the environment
* Need for acid cleaning
* Exposure of personnel to treatment and cleaning chemicals
* Need to purchase, store and dispose of hazardous teratment and cleaning chemicals
103
Magnetic Water Testing reduces:
* Waterside corrosion rate
* PMS man-hours
* Maintenance cost
104
Magnetic Water Testing increases:
* Boiler life
* Boiler efficiency
* Operating time between waterside inspections
105
Utilizing MWT, boiler water is maintained within set parameters. These parameters are:
* Alkalinity testing (pH): 8 to 11.5
* Total dissolved solids (TDS): below 1000ppm
* Chloride: less than 10 ppm
106
\_\_\_\_\_\_\_\_\_ causes a pitting corrosion in the boiler.
Chloride
107
The presence of ______ indicates saltwater in the system.
Chloride
108
Saltwater entry usually occurs at leaks in ______ in the system.
raw water heat exchangers
109
When the water in a boiler turns to steam, the minerals which are in the water remain. If left untreated, these minerals build up on the tubes forming \_\_\_\_\_.
Scale
110
The ____ of the water indicates the acidity or alkalinity of the water.
pH
111
On a pH scal ranging from 0-14, _____ is neutral.
7
112
Any value of pH below seven indicates that the water is \_\_\_\_\_\_.
Acidic
113
The lower the pH value the stronger the \_\_\_\_\_.
Acid
114
Boiler water with a low pH can lead to \_\_\_\_\_.
Acidic Corrosion
115
A pH value above seven indicates that the water is \_\_\_\_\_.
Alkaline
116
The higher the pH value, the higher the \_\_\_\_\_\_.
Alkalinity
117
Boiler water with excessively high pH (11.5 plus) leads to \_\_\_\_\_\_\_\_.
Caustic Embrittlement
118
Boiler water testing for chloride is only required on cutters with raw water heat exchangers in the condensate return system and without \_\_\_\_\_\_.
Salinity (chloride) Detection Systems
119
Once every ____ hours on a steaming boiler, sample the makeup feedwater, condensate tank and the boiler water.
24 Hours
120
\_\_\_\_\_\_\_\_ indicate the level of contaminates the water contains.
Total Dissolved Solids (TDS)
121
When the pH rises above the set range or our TDS rises above 1000 ppm, a ______ is performed to drop the level back to the desired range.
Surface Blowdown
122
For a "Bottom Blowdown" to be effective, take the boiler off line for ____ minutes to allow settling of the sludge.
30 Minutes
123
Once a boiler is stablized with MWT, water chemistry usually remains within the recommended ranges for _____ days.
several
124
Major waterside problems that occur in feedwater and boiler water are:
* High or low pH levels (acidic corrosion or caustic corrosion)
* Hardness (scale formation)
* Chloride (pitting)
125
The feedwater supply system consist of four major components:
* Feed Pump Set
* Feed stop and check valve
* Feedwater pressure indicating gauge
* Feedwater strainer
126
The feedwater pump set includes the following components mounted on the channel base:
* Centrifugal feedwater pump
* Motor and drive coupling
* Coupling (mounted on a channel base)
127
Used to isolate the boiler from the feedwater system during those times of boiler nonuse.
Feed stop valve
128
Used to prevent back pressure to the feedwater system while the pump is off.
Feed check valve
129
Test the feedwater supply system on a ______ basis.
Daily
130
Boilers are fitted with a MWT per \_\_\_\_\_\_.
SHIPALT 378-A-306
131
Feedwater testing includes:
* Alkalinity testing (pH)
* Total Dissolved Solids (TDS) of the boiler
* Hot well
* Makeup water
132
The recommended ranges for the boiler water parameters using MWT are:
* Ph tester 8-11.5
* TDS tester 1000 ppm or two times make-up TDS which ever is greatest
133
After performing a blowdown, wait at least ____ hours before testing again to allow make-up to enter the system and dilute the feedwater.
12 hours
134
The chloride test uses _____ as the titrant.
silver nitrate
135
Alkaline test procedure : Draw a ______ sample of boiler water to be tested.
150 milliliter (ml)
136
Alkaline test procedure: Allow sample to cool to ___ degrees fahrenheit.
100 degrees F
137
Alkaline test procedure: Remove protective cap from the tester and immerse _____ inches into the sample.
1 to 3.5 inches
