Operations set 1

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304.Chapter (6) 304.Draft is the difference in pressure between two points that causes air or gases of combustion to flow.

True

307.Mechanical draft is produced by a fan or blower

True

308.Air is necessary for combustion process to take place.

True

309.Dampers can be used to control the flow of air and gases of combustion.

True

311.The amount of natural draft generated is affected by the height of the chimney.

True

312.The two types of mechanical draft are forced and induced

True

314.A variable-speed drive (VSD) is a motor controller used to vary the frequency of the electrical signal supplied to an AC motor.

True

315.Balanced draft is a mechanical draft from fans located before and after the boiler

True

317.Some boilers have combination forced and induced draft fans

True

319.A cool stack condition can result in condensation of water vapor in the gases of combustion.

True

320.Natural draft produces greater amounts of draft in the winter than in the summer

True

321.18.When using a manometer to measure draft, the liquid level in one leg is com- pared to the liquid level in the other leg.

True

322.Proper control of draft results in higher combustion efficiency

True

323.The amount of draft determines the rate of combustion.

True

342.Boiler water treatment is required for makeup water introduced to the boiler.

True

344.Dissolved solids are impurities such as calcium. silica, and iron dissolved in solution.

True

4.In a Scotch marine boiler, the gases of combustion pass through tubes that are surrounded by water.

True

5.Oxygen is needed to burn fuel.

True

51.The steam pressure gauge must be connected to the highest part of the steam side of the boiler.

True

53.A slow gauge reads less pressure than is actually in the boiler.

True

54.Live steam allowed to enter the Bourdon tube of a steam pressure gauge will damage the gauge.

True

55.The water column should be blown down once a shift.

True

57.With the boiler at its NOWL, the gauge glass is approximately half full.

True

58.The purpose of the water column is to reduce the turbulence of the boiler water to obtain a more accurate reading of the water level in the gauge glass.

True

59.In low pressure steam boilers, two methods of determining water level are try cocks and gauge glasses.

True

62.With water at the NOWL, the middle try cock discharges a mixture of water and steam when opened.

True

64.If the top line to the gauge glass is closed or clogged, the glass will fill with water.

True

68.A high surface tension on boiler water can lead to foaming.

True

SURFACE BLOWDOWN VALVE

___Used to remove impurities from the surface of the water in a steam and water drum.

SOOT BLOWERS

___Used to remove soot from around tubes to increase boiler efficiency. Mostly found on water tube boilers.

CONDENSATE PUMP

___Used to return condensed steam to the open feedwater heater

MANUAL RESET VALVE

___Used to secure the gas in the event of a low water condition or a pilot flame failure on a low pressure gas system.

GAS PRESSURE REGULATOR

___Used to supply gas to the burner at the required pressure needed for combustion of the gas.

SUSPENSION SLING

___Used to support the drum of the HRT boiler.

GLOBE VALVE

___Used to take a piece of equipment out of service for maintenance. Used in conjunction with a bypass line and bypass valve.

DEADWEIGHT TESTER

___Used to test a pressure gauge so that it can be recalibrated.

FLASH TANK

___Used with a continuous blowdown system to recover the flash steam from the water being removed from the steam and water drum.

INTERLOCK

___Used with burner controls to ensure proper operating sequence.

ECONOMIZER

___Uses the gases of combustion to heat the feedwater.

SUPERHEATER DRAIN

___Valve found on the superheater header outlet. Used to maintain flow throughout the superheater during start-up and shutdown.

AUTOMATIC NONRETURN VALVE

___Valve located on the steam line closest to the shell of the boiler that cuts the boiler in on the line and off-line automatically. This valve also protects the system in the event of a large steam leak on any boiler.

WATER COLUMN BLOWDOWN VALVE

___Valve on the bottom of the water column used to remove sludge and sediment that might collect at the bottom of the water column.

MAIN STEAM STOP VALVE

___Valve or valves found on the main steam line leaving the boiler.

QUICK-CLOSING VALVE

___Valve that requires a one-quarter turn to be fully open or closed.

SLOW-OPENING VALVE

___Valve that requires five full turns of its handwheel to be fully open or closed.

GATE VALVE

___Valve used on boilers as the main steam stop valve that when open offers no restriction to flow. Must be wide open or fully closed.

GAUGE GLASS BLOWDOWN VALVE

___Valve used to remove any sludge and sediment from gauge glass lines.

POP-TYPE SAFETY VALVE

___Valve with a predetermined popping pressure.

ROTOMETER

___Variable-area flow meter that measures the flow of a fluid.

SMOKE DENSITY

___Varies from clear to dark. Determined by the amount of light that passes through the smoke as it leaves the boiler.

WATERWALL

___Vertical or horizontal tubes found in the furnace area of water tube boilers that lengthen the life of the refractory.

HIGH AND LOW WATER ALARM

___Warns the operator of high or low water.

NOWL (NORMAL OPERATING WATER LEVEL)

___Water level carried in the boiler gauge glass during normal operation (approximately one-third to one-half glass).

HYDROSTATIC PRESSURE

___Water pressure per vertical foot (.433) exerted at the base of a column of water.

ION (ZEOLITE) EXCHANGER

___Water softener that uses zeolite to soften water for use in the boiler.

HYDROSTATIC TEST

___Water test made on a boiler after repair work on the steam or water side or overheating of boiler metal.

FEEDWATER

___Water that is supplied to the steam boiler.

MAKEUP WATER

___Water that must be added to the boiler to make up for leaks in the system, water that is lost through boiler blowdowns, or condensate that is dumped because of contamination.

EROSION

___Wearing away of metal caused by the wet steam.

U-TUBE MANOMETER

___When filled with mercury, used to measure vacuum. U-tube manometers are calibrated in inches.

70.Boilers equipped with a quick-opening valve and a slow-opening valve must have the quick-opening valve closest to the boiler.

True

72.A high water level in the boiler can lead to carryover.

True

74.To correct a high water level condition in the boiler, the operator can open the bottom blow down valve.

True

75.Bottom blowdown valves are used when dumping the boiler.

True

76.A fusible plug is the last warning the operator has of a dangerous low-water condition in the boiler.

True

77.The core of the fusible plug melts at approximately 450°F.

True

78.The boiler vent is located at the highest part of the steam side of the boiler.

True

8.Steam leaves the boiler through the main steam line.

True

80.The boiler vent should be open when filling the boiler with water.

True

81.The pressure control is located at the highest part of the steam side of the boiler.

True

82.The pressure control must be mounted in a vertical position to ensure accurate operation.

True

85.The operating range is obtained by adjusting the differential pressure setting and either the cut-in pressure setting or the cut-out pressure setting on the pressure control.

True

Chapter (1) 1.Steam is formed when water is heated to its boiling point.

True

Chapter (2) 46.Boiler fittings are components attached directly to the boiler.

True

Chapter (3) 126.A high water level condition in the boiler could lead to water hammer

True

Chapter (4)166.A nonreturn valve allows a boiler to be cut-in on-line or off-line automatically as the boiler pressure changes on startup or shutdown.

True

Chapter (5)196. Fuel oil and gas are the most commonly used fuels in low pressure boilers.

True

A _______ is the scheduled shutdown of a processing unit for major repairs and or upgrades, inspecting piping and vessels for corrosion and erosion and to verify the proper operation of safety equipment

Turnaround

BALANCED DRAFT

___When the intake damper is automatically controlled by the pressure in the furnace. Furnace pressure is maintained slightly below atmospheric pressure.

LOW WATER

___Whenever the water level in the gauge glass is below the NOWL.

BRITISH THERMAL UNIT (BTU)

___A measurement of the quantity of heat. The quantity of heat necessary to heat one pound of water to 1°F.

CONDUCTION

___A method of heat transfer in which heat moves from molecule to molecule

RADIANT SUPERHEATER

___A nest of tubes that the saturated steam passes through to acquire heat.

INTERNAL OVERFLOW

___A pipeline located in an open feedwater heater that prevents the water level from exceeding a fixed level and flooding the system.

BYPASS LINE

___A pipeline that passes around a control, heater or steam trap. Used so that a plant can operate while equipment is serviced or repaired.

DATA PLATE

___A plate that must be attached to a safety valve containing data required by the ASME code.

LIME-SODA PROCESS

___A process that uses lime and soda ash to soften water.

STOPCOCK

___A quick-opening or closing valve usually found on gas lines.

HOT WELL

___A reservoir located at the bottom of a condenser where condensate collects

ZEOLITE

___A resin material that is used in the process of softening water

BOILER START-UP

___A sequence of operations completed when preparing a steam boiler for service.

BOILER SHUTDOWN

___A sequence of operations completed when taking a boiler off-line.

SURFACE CONDENSER

___A shell-and-tube vessel used to reduce the exhaust pressure on the outlet end of turbines or engines.

PNEUMATIC SYSTEM

___A system of control that uses air as the operating medium.

BENT-TUBE BOILER

___A water tube boiler with more than one drum in which the tubes connect the drums.

SLUDGE

___Accumulation residue produced from impurities in water.

CALIBRATE

___Adjusting a pressure gauge to conform to a test gauge.

OVERFEED STOKER

___Air introduced over the fire to aid in complete combustion. Used mostly when burning soft coal that has a high volatile content.

EXCESS AIR

___Air more than the theoretical amount of air needed for combustion.

SECONDARY AIR

___Air needed to complete the combustion process.

PRIMARY AIR

___Air supplied to the burner that regulates the rate of combustion.

WEIGHT-TYPE ALARM WHISTLE

___Alarm whistle which signals high or low water by the gain or loss of buoyancy of weights in water within the water column.

AIR TO FUEL RATIO

___Amount of air and fuel supplied to the burner over high and low fire.

FIRING RATE

___Amount of fuel the burner is capable of burning in a given unit of time.

FURNACE VOLUME

___Amount of space available in a furnace to complete combustion

STEAM TRAP

___An automatic device that removes gases and condensate from steam lines and heat exchangers without the loss of steam.

FLY ASH PRECIPITATOR

___An electric device that traps and holds fly ash until it is properly disposed of.

SOLENOID VALVE

___An electromagnetic valve positioned open or closed.

SOLID STATE

___An electronic system using transistors in place of electronic tubes.

SMOKE INDICATOR

___An indicating or recording device that shows the density of the smoke leaving the chimney.

RECORDER

___An instrument that records data such as pressures and temperatures over a period of time.

COAL BUNKER

___An overhead bin where large quantities of coal are stored

COMBUSTIBLE MATERIAL

___Any material that burns when it is exposed to oxygen and heat.

HEAT EXCHANGER

___Any piece of equipment where heat is transferred from one substance to another.

NONVOLATILE

___Any substance not easily vaporized under average temperature.

WATERWALL BLOWDOWN VALVE

___Approved valve used to remove sludge and sediment from waterwalls and waterwall headers.

PRESSURE CONTROL

___Attached to the highest part of the steam side of a boiler to control its operating range.

CHECK VALVE

___Automatic valve that controls the flow of a liquid in one direction.

PURGE PERIOD

___Before ignition and after burner shutdown when explosive combustibles are removed.

WARPING

___Bending or distortion of boiler or superheater tubes, usually caused by overheating.

WATER TUBE BOILER

___Boiler that has water in the tubes with heat and gases of combustion around the tubes.

FIELD-ERECTED BOILER

___Boiler that must be erected in the field because of its size and complexity.

HIGH PRESSURE STEAM BOILER

___Boiler that operates at a steam pressure over 15 psi and over 6 boiler horsepower.

EXTERNAL TREATMENT

___Boiler water treated before it enters the boiler to remove scale-forming salts, oxygen and noncondensable gases.

MULTIPLE-PASS BOILER

___Boilers that are equipped with baffles to direct the flow of the gases of combustion so that the gases make more than one pass over the heating surfaces.

LOW PRESSURE STEAM BOILER

___Boilers that operate at a steam pressure of no more than 15 psi.

FEEDWATER TREATMENT

___Can be internal, using chemicals, or external, using water softeners. Protects boiler from scale and corrosion.

SOOT

___Carbon deposits resulting from incomplete combustion.

BOILER EXPLOSION

___Caused by a sudden drop in pressure (failure on the steam side) without a corresponding drop in temperature.

SURFACE TENSION

___Caused by impurities on the top of the water in the steam and water drum.

NATURAL DRAFT

___Caused by the difference in weight between a column of hot gases of combustion inside the chimney and a column of cold air of the same height outside the chimney.

RINGELMANN

___Chart used as a means of determining smoke density.

LIGNITE

___Coal with a low heating value (BTU content) and a high moisture content.

ASME CODE

___Code written by the American Society of Mechanical Engineers that controls the construction, repairs and operation of steam boilers and their related equipment

GAS MIXING CHAMBER

___Where air and gas mix before they enter the furnace in low pressure gas burners.

BLOWDOWN TANK

___Coded tank vented to the atmosphere that protects sewer lines from boiler pressure and high temperature when blowing down.

BURNING IN SUSPENSION

___Combustion of a fuel when burned in air without support.

PACKAGE BOILER

___Comes completely assembled with its own feedwater pumps, fuel system and draft fans.

STEAMBOUND

___Condition that occurs when the temperature in the open feedwater heater gets too high and the feedwater pump cannot deliver water to the boiler.

BOURDON TUBE

___Connected by linkage to a pointer that registers pressure inside pressure gauges.

FRONT HEADER

___Connected to the steam and water drum by downcomer nipples

PROGRAMMER

___Control that puts the burner through a firing cycle.

FEEDWATER REGULATOR

___Control used to maintain a NOWL that cuts down the danger of high or low water.

VAPORSTAT

___Control with a large diaphragm that makes it highly sensitive to low pressure.

BYPASS DAMPER

___Controls the air temperature in air heaters to prevent corrosion.

COAL FEEDER

___Controls the flow of coal entering the pulverizer

HYDRAULIC COUPLING

___Coupling between the drive element and fan or pump.

FLASH STEAM

___Created when water at a high temperature has a sudden drop in pressure.

SCALE

___Deposits caused by improper boiler water treatment.

ALKALINITY

___Determined by boiler water analysis. Boiler water with a PH over 7 is considered alkaline

MAWP (MAXIMUM ALLOWABLE WORKING PRESSURE)

___Determined by the design and construction of the boiler in conformance with the ASME code.

FLAME SCANNER

___Device found on a boiler that proves pilot and main flame.

GAUGE GLASS

___Device installed on water column to visually check the water level (may be tubular or flat). Lowest visible level must be 3 inches above the tubes on horizontal fire tube boilers.

NORMAL OPERATING CONTROL

___Device that controls pressure or temperature in a specific range

INSTRUMENT (BOILER)

___Device that measures, indicates, records and controls boiler room systems.

SCANNER

___Device that monitors the pilot and main flame of the furnace.

STEAM SEPARATOR

___Device used to increase the quality of steam. Found in the steam and water drum.

GAS LEAK DETECTOR

___Device used to locate gas leaks in a boiler room.

BAFFLES

___Direct the path of the gases of combustion so that the maximum heat will be absorbed by the water before the gases of combustion enter the breeching and chimney.

EXHAUSTER

___Discharges a mixture of coal and warm air to the burner.

COAL RAM

___Distributes coal evenly into the center retort on underfeed stokers and forces the coal up to the top where it is burned.

INDUCED DRAFT

___Draft that is produced mechanically using a fan located between the boiler and the chimney.

SAFETY VALVE BLOWDOWN

___Drop in pressure between popping pressure and reseating pressure (usually 2 to 8 psi below popping pressure).

BREECHING

___Duct connecting boiler to chimney.

PIPELINE HEATER

___Electric heater attached to the fuel oil line in order to maintain proper fuel oil temperature (viscosity) for moving fuel oil.

CHEMICAL ENERGY

___Energy in the fuel converted to heat energy during the combustion process.

AUXILIARIES

___Equipment necessary for the operation of a boiler

HEAT RECOVERY SYSTEM

___Equipment that is installed to reclaim heat that is normally lost during the blowdown process.

HEATING VALUE

___Expressed in BTU's per gallon or per pound. Heating value varies with the type of fuel used.

RIVETS

___Fasteners used to connect steel plates.

FLAREBACK

___Flames discharging from the boiler through access doors or ports caused by delayed ignition or furnace pressure buildup.

CENTRIFUGAL FORCE

___Force caused by a rotating impeller that builds up in a centrifugal pump. Most boiler feed pumps are this type.

CHEMICAL COMPOUND

___Formed when two or more chemical elements combine into a new substance.

THROUGH STAYS

___Found on fire tube boilers (HRT and scotch marine) to keep front and rear tube sheets from bulging.

REAR HEADER

___Found on straight-tube water tube boilers. Connected to front header by water tubes

BLOWDOWN VALVES

___Found on the boiler blowdown line at the lowest part of the water side of the boiler.

SINUOUS HEADER

___Found on water tube boilers. Tubes are expanded, rolled and beaded into front and rear headers.

IMPINGMENT (FUEL OIL)

___Fuel oil striking brickwork or the boiler heating surface that results in formation of carbon deposits and smoke.

INTERNAL FURNACE

___Furnace that is located within the boiler and is surrounded by water in the scotch marine boiler.

NONCONDENSABLE GASES

___Gases found in boiler makeup water (oxygen) and in condensate returns.

GASES OF COMBUSTION

___Gases produced by the combustion process

PRODUCTS OF COMBUSTION

___Gases that are formed as a fuel is burned in the furnace.

PULVERIZING MILL

___Grinds coal to the consistency of talcum powder before it is delivered to the furnace, where it burns in suspension.

SPALLING

___Hairline cracks in boiler brickwork (refractory) due to changes in furnace temperature.

ANTHRACITE COAL

___Hard coal that has a high fixed carbon content.

FIRE TUBE BOILER

___Has heat and gases of combustion passing through tubes surrounded by water

PYROMETER

___High-pressure thermocouple used to measure furnace temperatures.

PACKING GLAND

___Holds packing or seals in place on valves and pumps to minimize leakage.

EXPANSION BENDS

___Installed on boiler main steam lines to allow for expansion and contraction of the lines.

MANOMETER

___Instrument used to measure boiler draft.

THERMOMETER

___Instrument used to measure temperature (degree of heat). Calibrated in degrees Celsius or degrees Fahrenheit.

FYRITE ANALYZER

___Instrument used to measure the percentage of carbon dioxide in the gases of combustion.

INFRARED

___Invisible light rays produced by the combustion process and detected by a flame scanner.

HEAT ENERGY

___Kinetic energy caused by molecular motion within a substance

ASH HOPPER

___Large receptacle used to store ashes until they can be disposed of.

BOILER VENT

___Line coming off the highest part of steam side of the boiler that is used to vent air from the boiler when filling with water and when warming the boiler. Also used to prevent a vacuum from forming when taking the boiler off-line. Also known as air cock.

EQUALIZING LINE

___Line used to warm up the main steam line and equalize the pressure around the main steam stop valve.

FEEDWATER LINES

___Lines leaving the open feedwater pump and going to the boiler.

MODULATING PRESSURE CONTROL

___Located at the highest part of the steam side of the boiler and sends a signal to the modulating motor that controls firing rate.

CONVECTION SUPERHEATER

___Located in a boiler and receives heat from convection currents

MUD DRUM

___Lowest part of the water side of a water tube boiler.

POUR POINT

___Lowest temperature at which fuel oil flows as a liquid.

IGNITION ARCH

___Made of refractory material that absorbs the heat from the fire and radiates it back to the green coal.

INSULATION

___Material used to cover steam, water, and fuel oil lines to cut down on radiant heat losses.

SAFETY VALVE CAPACITY

___Measured in pounds of steam per hour safety valves can discharge.

COAL SCALE

___Measures and records the amount of coal fed to stoker-fired or pulverized coal fired boilers.

CONDENSATE TANK

___Where condensed steam (water) is stored before it is delivered back to the open feedwater heater by the condensate pump

PRESSURE-REDUCING STATION

___Where higher pressure steam is reduced in pressure for plant process.

GRATES

___Where the combustion process starts in a coal-fired furnace.

VARIABLE-AREA FLOW METER

___Measures the flow of a substance by how much resistance is created by a float or piston which changes the area (size) of the flow path.

FORCED DRAFT

___Mechanical draft produced by a fan supplying air to the furnace.

COAL CONVEYOR

___Mechanism on a stoker that moves coal to the coal scale.

FLOW METER-

___Meter used to measure the flow of steam or water in the system.

HEAT TRANSFER

___Movement of heat from one substance to another that can be accomplished by radiant conduction or convection.

TURBULENCE

___Movement of water in the steam and water drum.

INCOMPLETE COMBUSTION

___Occurs when all the fuel is not burned, resulting in the formation of smoke and soot.

SPONTANEOUS COMBUSTION

___Occurs when combustible materials self-ignite.

FURNACE EXPLOSION

___Occurs when fuel or combustible gas build up in the fire side of the boiler.

CENTRIFUGAL PUMP

___Works on the principle of centrifugal force that is converted into pressure.

Waste

______Water is water used by a process that has become contaminated

COMPRESSIVE STRESS

___Occurs when two forces of equal intensity act from opposite directions, pushing toward the center of an object. Fire tubes in a fire tube boiler are subjected to compressive stress.

TENSILE STRESS

___Occurs when two forces of equal intensity act on an object, pulling in opposite directions. Affects boiler plates and staybolts.

SHEAR STRESS

___Occurs when two forces of equal intensity act parallel to each other but in opposite directions.

VERTICAL FIRE TUBE BOILER

___One-pass boiler that has fire tubes in a vertical position. Vertical fire tube boilers are classified as wet-top or dry-top.

MANHOLE

___Opening found on the steam and water side of a boiler that is used for cleaning and inspection of the boiler.

HUDDLING CHAMBER

___Part on a safety valve that increases the area of the safety valve disc, thus increasing the total upward force, causing the valve to pop open.

SEDIMENT

___Particles of foreign matter present in boiler water.

CARRYOVER

___Particles of water that flow with the steam into the main steam line.

Define bonding?

connecting two objects with metal usually piece of copper wire

Define grounding

consists of connecting an object to earth with metal usually copper wire

Attempting to open a motor controlled valve manually

hand or back injuries damage to valave and motor loss of process control potential release of a hazardous substance

list two factors important to process technicians involving energy

heat conservation and safe usage

Discuss why it is important for a process unit to avoid heat losses

heat is energy produced by burning fuel reduce heat losses and you reduce fuel cost

_____ are left over product from another shipment still remaining in the cargo tank

heels

Level

- Ultrasonic and radiation detectors are classified as non-contacting -Radiation level detectors have two basic parts: a radiation transmitter and a radiation detector.

Where two or more traps discharge into the same header, what needs to be provided in the discharge line from each trap?

-a stop valve

In regards to a liquid expansion steam trap, what is the purpose of the sealing bellows? The relief spring? The adjustment screw?

-acts as a packless gland to prevent leakage from the tube -protect from water hammer and over-expansion -adjust the outlet temp of the discharge

Where must drip trap stations be installed?(3)

-ahead of any risers and expansion joints or bends -at the end of steam mains -every 90 to 150m along steam piping

Where does the moisture separated by a steam purifier go?

-it's collect at the bottom of the purifier, than out through a drain to a trap that discharges it to the condensate system

In what way does trap capacity depend on the size of the discharge orifice? On the temp. of the condensate?

-larger discharge orifice=greater capacity and vice-versa -higher temp=lower capacity and vice versa

What precautions should be taken to ensure a steam line is completely drained of condensate during warm up? (4)

-line blocked completely at both ends -slowly open each low point drain -ensure traps are in service -ensure all condensate drained from pressurized side of steam supply valve

INTERNAL FEEDWATER LINE

___Perforated line located at the NOWL in the boiler that distributes the relatively cool feedwater over a large area to prevent thermal shock to the boiler metal.

ACCESSORY

___Piece of equipment not directly attached to the boiler but necessary for its operation

DISCHARGE PIPING

___Piping attached to the outlet side of a safety valve that conveys steam to the atmosphere.

ORIFICE PLATE

___Plate with a fixed opening that is installed in a pipeline to give a certain pressure drop across the opening where liquid or steam is flowing.

HIGH FIRE

___Point of firing cycle when burner is burning the maximum amount of fuel per unit of time.

LOW FIRE

___Point of firing cycle where burner is burning the minimum amount of fuel per unit of time.

RECIPROCATING PUMP

___Positive-displacement pump used to pump liquids.

BOILER CAPACITY

___Pounds of steam per hour that a steam boiler is capable of producing.

POPPING PRESSURE

___Predetermined pressure at which a safety valve opens and remains open until the pressure drops.

GAUGE PRESSURE

___Pressure above atmospheric pressure that is read on a pressure gauge and is recorded as psi or psig.

ATMOSPHERIC PRESSURE

___Pressure at sea level (14.7 psi).

VACUUM GAUGE

___Pressure gauge used to measure pressure below the atmosphere that is calibrated in inches of mercury.

SUCTION PRESSURE

___Pressure on the liquid at the suction side of a pump.

WINDBOX (PLENUM CHAMBER)

___Pressurized air chamber that supplies air to a furnace.

COUNTERFLOW

___Principle used in heat exchangers where the medium being heated flows in one direction and the medium supplying the heat flows in the opposite direction.

CONDENSE

___Process whereby steam turns back to water after the removal of heat.

SIPHON

___Protective device used between the steam and Bourdon tube in a steam pressure gauge.

AIR FLOW SWITCH

___Proves that primary air is supplied to the burner.

PROXIMATE ANALYSIS

___Provides information regarding moisture content, volatile matter, fixed carbon and ash content of coal.

PROPORTIONING CHEMICAL FEED PUMP

___Pump that can be adjusted to feed chemicals to a boiler over a 24-hour period.

FUEL OIL PUMP

___Pump that takes fuel oil from the fuel oil tank and delivers it to the burner at the proper pressure.

OPERATING RANGE

___Range that must be set when using an ON/OFF combustion control in order to prevent extremes in firing rate.

FOAMING

___Rapid fluctuations of the boiler water level that can lead to priming or carryover. Caused by impurities on the surface of the boiler water.

MODULATING MOTOR

___Receives signals from the modulating pressure control and repositions the air to fuel ratio linkage.

STRIP CHART-

___Recording chart that records temperatures and pressures in the system.

WATER COLUMN

___Reduces fluctuations of boiler water to obtain a better reading of the water level in the boiler gauge glass. Located at the NOWL.

GRADE

___Refers to the size, heating value and ash content of coal.

COMBUSTION CONTROL

___Regulates the air to fuel ratio supplied to the burner.

DUPLEX STRAINERS

___Remove solid particles from the fuel oil in fuel oil systems.

VENT CONDENSER

___Removes oxygen and other noncondensable gases in a deaerating feedwater heater.

BOILER LAY-UP

___Removing a boiler from service for an extended period of time. A boiler can be laid up wet or dry.

DESUPERHEATING

___Removing heat from superheated steam to make it suitable for process.

BOX HEADER

___Requires staybolts to prevent the headers from bulging. Found on older water tube boilers.

NONADHERING SLUDGE

___Residue formed in a boiler when scale-forming salts are created by adding feedwater chemicals.

TUBULAR GAUGE GLASS

___Round gauge glass used for pressures up to and including 250 psi.

SCALE-FORMING SALTS

___Salts such as calcium carbonate and magnesium carbonate that when in solution tend to form a hard, brittle scale on hot surfaces.

TRY COCKS

___Secondary way of determining the water level.

CYCLONE SEPARATOR

___Separates water droplets from steam using centrifugal force and by changing direction.

OUTSIDE STEM AND YOKE VALVE (OS&Y)

___Shows by the position of the stem whether it is open or closed. Used as boiler main steam stop valves.

PROVING PILOT

___Sighting the pilot through the scanner to verify that the pilot is lit.

CRACKING OPEN

___Slowing opening a steam valve to allow pressure to equalize.

FLY ASH

___Small particles of noncombustible material found in gases of combustion.

BITUMINOUS COAL

___Soft coal that has a high volatile content.

RETORT

___Space below the grates of an underfeed stoker.

PUMP CONTROLLER

___Starts and stops a feedwater pump, depending on the water level in the boiler.

SUPERHEATED STEAM

___Steam at a temperature above its corresponding pressure.

SATURATED STEAM

___Steam at a temperature that corresponds with its pressure.

CONDENSATE

___Steam that has lost its heat and has returned to water

EXTRACTION STEAM

___Steam that is extracted from a steam turbine at a controlled pressure for process.

LIVE STEAM

___Steam that leaves the boiler directly without having its pressure reduced in process operations.

PROCESS STEAM-

___Steam used in the plant for manufacturing purposes.

AIR EJECTOR

___Steam-driven device that removes air and other noncondensable gases from the condenser, thus maintaining a higher vacuum.

AIR HEATER

___Supplies heated air for combustion. Located in the breeching between the boiler and chimney.

MERCURY SWITCH

___Switch in which the movement of mercury in a capsule controls the flow of electricity in a circuit.

RESET

___Switch that must be reset manually after tripping.

FEEDWATER PUMP

___Takes water from the open feedwater heater and delivers it to the boiler at the proper pressure.

FLASH POINT

___Temperature at which fuel oil, when heated, produces a vapor that flashes when exposed to an open flame.

AMBIENT TEMPERATURE

___Temperature of the surrounding air

QUALITY OF STEAM

___Term used to express the moisture content present in saturated steam. Quality of steam effects the BTU content of the steam.

EVAPORATION TEST

___Test that checks the operation of the low water fuel cutoff.

ACCUMULATION TEST

___Test used to establish the relieving capacity of boiler safety valves.

HEATING SURFACE

___That part of the boiler that has heat and gases of combustion on one side and water on the other.

MAIN HEADER

___That part of the system which connects boilers in battery and then distributes the steam to wherever it is needed.

TURBINE STAGES

___That part of the turbine where steam gives up its energy to the turbine blades. As the steam pressure drops, the stages (blades) become larger.

INTERNAL TREATMENT

___The addition of chemicals directly into the boiler water to control pitting, scale and caustic embrittlement.

CHEMICAL CONCENTRATION

___The amount of a specific chemical in the boiler water.

RATE OF COMBUSTION

___The amount of fuel that is being burned in the furnace per unit of time.

COMPLETE COMBUSTION

___The burning of all supplied fuel using the minimum amount of excess air.

CAUSTIC EMBRITTLEMENT

___The collection of high alkaline material that leads to breakdown and weakening of boiler metal.

DRAFT

___The difference in pressure between two points that causes air or gases to flow.

BOILER HORSEPOWER

___The evaporation of 34.5 pounds of water per hour from and at a feedwater temperature of 212°F.

LIGHTING OFF

___The ignition of the fuel.

IGNITION

___The lightoff point of a combustible material.

FIREBOX

___The part of the boiler where combustion of fuel takes place

POSTPURGE

___The passing of air through a furnace after normal burner shutdown.

PREPURGE

___The passing of air through a furnace prior to lightoff.

STEAM AND WATER DRUM

___The pressure vessel in a steam boiler that contains both steam and water

COMBUSTION

___The rapid union of oxygen with an element or compound that results in the release of heat.

THERMAL EFFICIENCY

___The ratio of the heat absorbed by the boiler to the heat available in the fuel per unit of time.

WATER SOFTENING

___The removal of scale-forming salts from water.

IMPELLER

___The rotating element found in a centrifugal pump that converts centrifugal force into pressure.

STEAM SPACE

___The space above the water line in the steam and water drum.

ABSOLUTE PRESSURE

___The sum of gauge pressure and atmospheric pressure

SYNCHRONIZE

___To balance out combustion controls before switching to automatic

ATOMIZE

___To break up liquid into a fine mist.

TOTAL FORCE

___Total pressure that is acting on an area, determined by diameter and pressure.

FITTINGS

___Trim found on the boiler that is used for safety, and/or efficiency

List four reasons for the collecting of unit samples.

1. Verification of steam composition 2. Verification of on-specific products 3. Troubleshooting process problems 4. Compare and calibrate online analyzers

Describe three ways analytical tests support process units.

1. Verifies unit is on specifications 2. Alerts technician to developing problems 3. Helps troubleshoot unit problems

267.The__ is the temperature at which fuel oil will burn continuously when exposed to an open flame.

A.fire point

297.The flame scanner proves the __ and main flame.

A.pilot

TUBE SHEET

___Tubes are rolled, expanded and beaded into front and rear tube sheets of HRT and scotch marine boilers and upper and lower tube sheets of vertical fire tube boilers.

BOILERS IN BATTERY

___Two or more boilers connected to a common steam header

245.When cleaning a fuel oil strainer, the __ must be carefully replaced to prevent air from entering the system.

B. gasket

176. Boiler main steam stop valves should be__ valves.

B. gate

339.High combustion efficiency produces the maximum amount of__ generated by the fuel.

B. heat

27.A__ is used to transfer heat from one substance to another without allowing the materials to mix.

B. heat exchanger

158.Excessive use of cold city makeup water reduces overall boiler efficiency because as the water must be__before use in the boiler.

B. heated

22.The__ is the part of the boiler with water on one side and heat on the other.

B. heating surface

118.The capacity of a safety valve is measured by the amount of steam that can be discharged per__.

B. hour

195.A(n) __is a device used to measure radiation emitted from an object

B. infrared thermometer

110.The best time to blow down a boiler to remove sludge and sediment is when the boiler is under a__.

B. light load

157.Water added to the boiler to replace water lost due to leaks and blowing down is known as__water.

B. makeup

328.. Forced draft and induced draft are two types of __ draft

B. mechanical

251.In a low pressure gas burner, gas is mixed with air in the__.

B. mixing chamber before the burner register

191.A thermodynamic steam trap opens and closes by a(n)

B. movable disc

184.A__ valve is a type of globe valve that allows a boiler to be cut in on-line automatically when the boiler pressure is at or above the header pressure.

B. nonreturn

276.To prevent smoke and to aid in complete combustion in the screw-feed stoker, __ air is provided using a separate damper control.

B. overfire

95.The steam pressure gauge on the boiler is calibrated to read__.

B. pounds per square inch

329.Mechanical draft is produced by __.

B. power-driven fans

294.Unburned fuel in a gaseous state is removed from the furnace by__.

B. purging the furnace

256.In a high pressure gas system, the plant pressure__ valve reduces gas pressure to line pressure used in the system.

B. regulating

86.The__ is the most important valve on a boiler

B. safety valve

156.The primary function of a low water fuel cutoff is to __.

B. shut down the burner if the water level drops below the safe operating level

159.An auxiliary low water fuel cutoff is installed__.

B. slightly below the primary low water fuel cutoff

151.A__ after each heating unit allows condensate to pass through to the return line

B. steam trap

187.Steam returning to the vacuum tank could cause the condensate pump to become__.

B. steambound

258.A __ is a mechanical device for feeding coal consistently to the burner.

B. stoker

150.The feedwater __valve should be located as close to the shell of the boiler as practical

B. stop

295.Unburned fuel oil that is heated in the furnace will__.

B. vaporize

193.A steam trap that fails to open causes the heating unit to become __.

B. waterlogged

24.A __ boiler has water in the tubes and heat and gases of combustion passing around the tubes.

B. watertube

104.If the desired cut-in pressure of the boiler is 6 psi and the desired cut-out pressure is 10 psi, the differential pressure setting must be _ psi.

B.4

147.When steam releases heat in a heat exchanger, it turns to __.

B.condensate

HORIZONTAL RETURN TUBULAR BOILER

___Type of fire tube boiler that consists of a drum suspended over the firebox.

139.An evaporation test is performed by opening the low water fuel cutoff blowdown valve by hand.

False

142.The makeup water feeder can be used as a feedwater regulator

False

16.Approximately 212 lb of air are required to bum a pound of fuel.

False

167.Heating units are designed to minimize heat loss from a building space.

False

171.A steam strainer should be located after a steam trap.

False

173.Expansion bends are used to route steam lines around obstacles.

False

175.Return steam traps are commonly found in modern boiler plants.

False

18.A low pressure boiler is a boiler that has an MAWP over 15 psi.

False

FLAT GAUGE GLASS

___Type of gauge glass used for pressure over 250 psi.

2.A boiler is an open metal container in which water is heated to produce steam or heated water.

False

20.A firebox boiler is a cylindrical scotch marine boiler.

False

201.A dirty strainer results in low suction readings.

False

204.Rotary cup burners can burn only No. 2 fuel oil.

False

208.In an air atomizing burner, steam and fuel are discharged to the burner for combustion.

False

213.A metal scraper is used to clean deposits on a fuel oil burner nozzle.

False

215.The manual reset valve in the gas system closes if the boiler has a high water level.

False

216.A fuel oil heater is required when using No. 2 fuel oil

False

220.Hard coal has a high volatile content

False

224.Grates are only needed in hand-fired coal boilers to support the coal.

False

227.Stokers were developed to reduce the amount of coal fed to the furnace.

False

232.Propane is lighter than air and requires special handling.

False

233.The viscosity of fuel oil is the temperature at which it will burn continually when exposed to an open flame.

False

234.The flash point of fuel oil is the temperature at which it will resist burning

False

235.It is best to burn fuel oil with a low flash point

False

242.The flame scanner proves the main flame only

False

305.Gases move from an area of low pressure to an area of high pressure.

False

306.The two types of draft are mechanical and forced.

False

310.Approximately 75 lb of air is required for every pound of fuel burned.

False

313.The induced draft fan is located on the front of the boiler.

False

316.The forced draft fan is located in the breeching.

False

343.Slug feeding is used to generate foam to prevent carryover.

False

47.Safety valves on steam boilers are designed to open slowly.

False

49.Safety valves are tested only by performing a try lever test.

False

50.A safety valve try lever test is performed with the boiler at 15 psi or higher.

False

52.A siphon is connected between the boiler and the steam pressure gauge to prevent water from entering the Bourdon tube.

False

56.The water column is used to indicate the water level in the blowdown tank.

False

60.Gauge glasses are calibrated in pounds per square inch

False

61.With water at the NOWL, steam is discharged from the bottom try cock when it is opened.

False

63.With water at the NOWL, water is discharged from the top try cock when opened

False

65.If the bottom line to the gauge glass is closed or clogged, the glass will be empty.

False

66.To ensure the lines to the gauge glass are clear, it is recommended that the gauge be blown down at least once a month.

False

67.The bottom blowdown line must be connected to the highest part of the steam side of the boiler.

False

69.Surface impurities are removed from the boiler by using the bottom blowdown valves

False

7.The steam system supplies water to the boiler.

False

71.Only watertube boilers have bottom blowdown valves.

False

73.When dumping a boiler, there should be maximum steam pressure in the boiler to force water from the boiler.

False

79.The safety valve should be used as a boiler vent for faster blowdown

False

83.A burner should always start up in high fire to ensure enough fuel for ignition.

False

DEAERATING FEEDWATER HEATER

___Type of open feedwater heater equipped with a vent condenser.

PSI (POUNDS PER SQUARE INCH)

___Unit of measurement used to express the amount of pressure present in a given structure or system.

MASTER CONTROL

___Unit that receives the primary signal and relays signals to individual control units.

THERM

___Unit used to measure BTU content of natural gas. A therm has 100,000 BTU.

RAW WATER

___Untreated water from wells or city water lines.

STEAM STRAINER

___Used before steam traps and turbine throttle valves to remove solid impurities.

MALLEABLE IRON

___Used for construction of water columns in boilers carrying a pressure between 250 psi and 350 psi.

TUBE BRUSHES

___Used in fire tube boilers to remove soot from inside of tubes.

CROSS "T"

___Used on connections on a water column for inspection of steam and water lines to ensure they are clean and clear.

PRESSURE-REDUCING GOVERNOR

___Used on low pressure gas burner systems to reduce the gas pressure to 0 psi.

FLEXIBLE JOINT

___Used to allow for expansion and contraction of steam or water lines.

GAS ANALYZER

___Used to analyze the gases of combustion to determine combustion efficiency.

84.Burners using fuel oil or gas should be adjusted so they are OFF for longer periods than they are ON to save fuel and keep furnace temperatures lower.

False

9.Steam that has given up its heat and turned back to water is boiler water.

False

BOILER TUBES

___Used to carry water or heat and gases of combustion. May be straight or bent tubes.

CONTINUOUS BLOWDOWN

___Used to control chemical concentrations and total dissolved solids in the boiler water.

COAL GATE

___Used to control the depth of coal entering the boiler furnace on chain grate stokers

DAMPER

___Used to control the flow of air or gases.

It is not necessary to check tank pressure during monitoring and maintenance activities for a hot oil system

False

List five causes of equipment failure

Faulty design, faulty selection, faulty installation, misalignment, excessive load, excessive heat, excessive lube oil particles and moisture

Know how to catch samples

Feed sample- Feed is under pressure. Hot representative sample Bottoms/Reflux- Open valve on suction side. Crack discharge til it warms up. Block vacuum/suction side. Then take sample

location between feed bottoms exchanger and the trim cooler

Fin Fan

223.Gases of combustion that contact boiler heating surfaces before combustion is completed cause soot and smoke

True

225.Smoke is a sign of incomplete combustion

True

226.Smoke is less of a problem when burning hard coal as compared to soft coal.

True

228.Stoker firing allowed the design of larger coal-fired boilers.

True

229.The type of fuel used determines the fuel system accessories required.

True

230.Purging the lines and nozzles of an air atomizing burner at the end of its firing cycle keeps lines and nozzles clean for the next starting cycle.

True

231.Natural gas is a colorless and odorless fossil fuel.

True

236.Pour point is the lowest temperature at which fuel oil will flow as a liquid.

True

237.A therm is the quantity of gas required to produce 100,000 Btu.

True

238.The temperature of No. 6 fuel in a fuel oil tank should be maintained at approximately 100°F to 120°F.

True

239.Fuel oil in the storage tank must be kept below its flash point temperature

True

240.The temperature of the fuel oil in the storage tank must be kept above the recom- mended pour point.

True

241.No.6 fuel oil must be heated to the proper temperature in order to burn

True

243.The furnace must be purged after any flame failure.

True

3.Water begins to boil at 212°F at atmospheric pressure.

True

CHIMNEY

___Used to create draft. Also an outlet to the atmosphere for the gases of combustion

GAS CALORIMETER

___Used to determine the BTU content of natural gas

STEAM TURBINE

___Used to drive boiler auxiliaries or generators in large plants.

FEEDWATER HEATER

___Used to heat feedwater before it enters the steam and water drum.

FUEL OIL HEATER

___Used to heat fuel oil so it can be pumped and is at the correct temperature for burning. Can be electric or steam.

PILOT

___Used to ignite fuel at the proper time in a firing cycle.

SUPERHEATER

___Used to increase the amount of heat in the steam.

GALVANOMETER

___Used to measure small electric currents

THERMOCOUPLE

___Used to measure temperatures in the system and send them back to a recording chart.

RELIEF VALVE

___Used to protect liquid systems from excessive pressure.

MICA

___Used to protect the flat gauge glass from the etching action of steam and water.

FREE-BLOWING DRAIN

___Used to remove condensate from the main steam line.

what is check sample

if a sample yields abnormal information, a second sample (check sample) is caught and submitted for analysis to check for a unit problem or contaminated sample

Describe two symptoms of a 16 percent oxygen level?

impaired judgment and impaired breathing

List three advantages of using control charts?

improved product quality, increased quality consciousness, cost reduction, data based decisions and predictable processes

Describe some activities that would be considered hot work

mobile equipment, chipping, sanding, electric tools and welding or open flames

List three simple methods for troubleshooting steam traps

observation, sound, and temperature measurements

Why is nitrogen considered a killer gas

odorless, colorless, widely used in plants and displaces oxygen

What information should be included on the sample label or tag

should contain the process unit name, sample name, date, time collected, and analytical tests required

Explain why liquids sold by volume have their volumes adjusted at 60 degree

to standardized the volume measurement of most hydrocarbons

What is the purpose of a blind test

to verify that all required blinds have been installed before anyone enters process equipment and to verify all blinds have been removed prior to unit startup

List four portable containers for transporting process material

tote bins, buckets, sacks, steel cylinder, portable tanks, boxes and drums

Distillation columns

tower trays condenser reboiler

Three hazards that might exist in a confined space are

toxic atmosphere, toxic chemicals, flammable materials, oxygen deficiency

Pneumatic instruments

use air pressure or a gas as the power source

safe work permit

used to insure the area is safe fore work to be performed and for communicating that information.

List two important predictive maintenance checks to make on electric motors

vibration and temperature

List four characteristics of lubricants

viscosity, temperature stability, chemical resistance and chemical composition

Leaving condensate in steam lines can cause _____

water hammer

wastewater

water that contains waste products on the form of dissolve or suspended solids

potable water

water that is safe to drink

Boiler feed water

water that sent to a boiler in order to produce steam

STAYBOLTS

___Bolts used in boilers to reinforce flat surfaces to prevent bulging.

REFRACTORY

___Brickwork used in boiler furnaces and for boiler baffles.

PERFECT COMBUSTION

___Burning of all the fuel with the theoretical amount of air. Can only be achieved in a laboratory.

PRESSURE GAUGE

___Calibrated in pounds per square inch. Used to indicate various pressures in the system.

List six types of containers used for material handling of product

bags and boxes, drums, tote bins, sacks, intermodal containers, cargo trailers, tank cars, storage tanks, barges, ships, gas cylinders

State the hazard of condensate in steam lines

water hammer

Treated water

water that has been filtered, cleaned and chemically treated

What is the purpose of the secondary baffles in a centrifugal steam separator?

-to reduce the whirling motion of the leaving steam

Most of the time there is a ______ behind equipment failure.

(Human Factor)

Piping and Instrumentation Drawing

- A piping and instrumentation drawing (P&ID) is a complex representation of the various units found in a plant - A P&ID, like a road map, can show intricate details of a unit that cannot easily be noticed during a walk-through - Techs will graudate to reading and using complex P&ID over the course of their training

List main vessels

-Column -Feed tank -Boiler -Reflux -Boiler feed water tank

True OR False? Trap discharge piping shall be designed to the same pressure as the inlet piping unless the discharge is vented to atmosphere, or is operated under low pressure and has no stop valves?

-true

List five physical tests

1. Flashpoint 2. Specific 3. API gravity 4. Viscosity 5. pH (6. Vapor Pressure)

The cost per year to US industry due to abnormal situation is

20 billion

Final Control Element Actuators

3 Basic Designs: 1. Pneumatically (air) operated - Diaphragm - Piston - Vane

Unit turnarounds occur about every ____ to ___ years

3 to 6

What is the percent of workplace fatalities due to failure to follow or have an energy isolation program?

6 percent

318.Draft is typically measured in pounds per square inch (psi).

False

Interlock

A device designed to prevent damage to equipment and personnel. It accomplishes this by stopping or preventing the start of certain equipment functions unless a preset condition has been met. There are two types of interlocks: softwire and hardwire. Hardwire interlocks can't be bypassed. They must be satisfied before the process they are part of can take place.

Multiple-choice a tall column means

A difficult separation

Explain how lock out of a piece of equipment is accomplished?

A padlock is placed through a gate or hasp covering the activating mechanism of an energy source or is applied in some other manner to prevent energy from being turned on

HANDHOLE

A part found on both fire tube and water tube boilers that is removed when cleaning the water side of the boiler.

Make up water

About 80% of water losses due to evaporation.

Explain how water gets into lubricants

Absorption, condensation, heat exchangers and free water entry

13. What are the advantages of automated analyzers? What are the disadvantages?

Advantages: of automated analyzers are that they analyze process material much faster than the laboratory and data is automatically uploaded into the unit database. The most important advantage is rapid sample analysis. Disadvantage: They need attention to keep them calibrated and operating properly and they are expensive, ranging from $25,000 to $100,000 or more per unit.

API?

American Petroleum Institute

Multiple-choice normal start up before except

Answer is not install operating aides

11. Name three appearance tests and how they are used.

Appearance tests are based on the appearance of a sample. Two of the most common appearance tests are color and haze. • Test for Color of Petroleum Products: Color specifications apply to many products, but in general, color provides an indication of contamination. • Saybolt Color Test: Is the physical measure of the clarity of a hydrocarbon and is used as an indication of the overall purity of the hydrocarbon. • Haze Test: This test is conducted to determine if samples are relatively free of entrained water or substances that cause haze.

What are the advantages of a standardized format for procedures?

Are that the familiarity bred by standardization makes it easier to follow the procedure and also easier to find information faster.

What information should be included on a sample label or tag?

Area Sample name Date Time

There are portions of procedures except

Arthur appendix title review section review section is not part of the portions procedure

If a person comes into contact with a nitrogen rich environment and dies, what is the most likely cause of death?

Asphyxiation

Law of composition

At constant pressure, compositions it's a bowling point, which that's the temperature

262.Soft coal is__.

B. bituminous coal with a high volatile content

______ are installed to keep unwanted materials out of the recently purged systems

Blinds

Reduce pressure in tower?

Causes an increase in boil up rate and OVHD production

269.In order to reduce the viscosity of fuel oil, it is necessary to__.

C. increase its temperature

336.A __ is a simple draft gauge consisting of a U-shaped glass tube

C. manometer

28.In the __, air mixes with fuel and bums

C. combustion chamber

155. The range of pressure on the vacuum switch is usually .

C. 2" to 8"

94.The total force on a safety valve 2 1/2" in diameter with a steam pressure of 15 psi is__.

C. 73.6

25.__ are used in boilers to direct the gases of combustion over the boiler heating surface

C. Baffles

119.__is when a safety valve opens and closes rapidly.

C. Chattering

287.__is the amount of fuel the burner is capable of burning in a given unit of time.

C. Firing rate

122.__causes false water level readings in the gauge glass.

C. Foaming

162.The feedwater regulator is located at the__.

C. NOWL

292.__air controls the combustion efficiency.

C. Secondary

194.__remove dirt and impurities that may cause the steam trap to malfunction.

C. Steam strainers

273.A__ is used to prevent damage to the transmission of a screw-feed stoker in the event of an obstruction clogging the feed screw.

C. shear pin or key

List four types of valves used in a control valve manifold.

Control valve, block valve, bypass valve, drain valve.

_______ is to remove traces of flammable, toxic, or corrosive materials from piping or equipment for maintenance, inspection, or other work

Clear up

Temperature to the column increases because pressure.The temperature controller should...

Closed/Pinch Back/ Decrease ?????

Controller

Controller can be operated in manual, automatic, or cascade control.

. Unit technical manual:

Contains detailed information about the unit process and equipment. It will include a process description, the process chemistry, unit limitations, information about major equipment (construction material, stress rating, dimensions, etc.) and a summary of the unit's instrument control strategy.

Chemicals used to treat water

Cooling tower water is very chemically treated sulfuric acid used to treat the water????

Cooling Tower

Cooling towers transfers heat energy to the outside air through the principle of evaporation. Upward direction in the symbol indicates cooling.

The cooling water system is a blank system

Cooling water system is a closed cycle

Cooling water system

Cools down water used to cool units down in the plant

__________ in the planned work will have to be determined

Critical paths

48.The safety valve should chatter to prevent damage to the disc.

False

283.A(n) __is a combustion control system that controls the amount of steam produced by changing the burner firing rate.

D. modulating control system

149.A__valve allows the flow of water in one direction only.

D. check

332.A __ is a device used to create resistance in order to regulate the flow of air and gases of combustion in a boiler.

D. damper

90.The area of a safety valve 4" in diameter is _ square inches

D. 12.5664

39.Water turns to steam at __°F at atmospheric pressure

D. 212

261.Hard coal is__.

D. anthracite coal with a high carbon content

96. Steam is prevented from entering the Bourdon tube of the pressure gauge by a(n) __

D. siphon

327.A __ is a steel chimney used to direct the flow of gases of combustion from the boiler to the atmosphere.

D. stack

105.Impurities that build up on the surface of the water in the boiler prevent__ from breaking through the surface of the water.

D. steam

List five examples of equipment function reduction

Defective product, reduced output, frequent stoppages, noisy operation, reduced speed, or unsafe conditions

A ____ is a device that fits over the rails and prevents oncoming tank cars from running into the spotted tank car

Derailer

Discuss the roles a process technician performs in the area of environmental compliance?

Detects spills and releases, assist in spill clean up, write incident reports, and assist plant environmental personnel or local, state, federal authorities with inspections and investigations

Transformer

Device used by industry to convert high voltage to low voltage. Problems are handled by the electrical department. Electrical breakers are designed to interrupt current flow if design conditions are exceeded. Breakers are not switches and should not be turned on or off. If a tripping problem occurs, the technician should call for an electrician. Fuses are devices designed to protect equipment from excess current. A thin strip of metal within the fuse will melt if design specifications are exceeded. During operational rounds, technicians check the ammeters inside the MCC for current flow to their electrical systems.

Distributive Control Systems

Distributive Control systems combine some of the most innovative technologies into an interactive network of intelligent microprocessors, application software, and communication networks.

What do the intials DCS stand for?

Distrubuted Control System

168.A globe valve should never be used as a main steam stop valve.

True

List six hidden defects that lead to equipment failure:

Dust, Dirt, Sticking, Abrasion, Looseness, Leakage, Corrosion, Erosion, Deformation, Scratches, Cracks, Temperature, Vibration, and Noise are the collection of abnormalities.

Discuss how a process unit ensures its customers to receive product while the unit is shut down

Either enough product must be in inventory for customers or plans prepared for purchasing product on the market. Most companies want to maintain or increases their market share, so careful thought and planning is given to building an inventory of products to provide for customer needs or contacting with another site to supply customers

Voltmeter

Electrical devices used to monitor voltage in an electrical system.

There are many different types of procedures except

Emergency safety administration start up procedures start up procedures is not one of its own it actually falls under administration

Define end point and initial boiling point

End point-are the highest temperature indicated when hydrocarbon are in a lab. Boiling point- is the temperature at which the first drop of material distilling fall into the receiver.

Explain why there is a greater for environmental releases during a shutdown

Environmental issues are a concern during a shutdown because there is a greater potential for chemical spills as process piping, equipment and vessels are drained and opened. The potential for unwanted environmental releases increases because changing pressures and temp. can cause joints to leak. Also, as systems are opened, materials which were not completely drained and purged from the system may contaminate the environment

Explain the advantages of running in equipment

Equipment is up to standard and dependable, making unit startup less stressful

OSHA

Except unit entry

Describe the three hazards of light ends?

Flammable, volatile, must be stored under pressure, and all have a low boiling point and viscosity

Process Symbols

Form the written flow language necessary for understanding how a specific process operates.

169.Gate valves offer no restriction to flow when open.

True

A _______ used to drain electricity to ground eliminates the static electricity hazard

Grounding cable

Explain how specific heat affects the operation of heat exchangers.

Heat exchangers have a specific surface area, metals of construction, and calculated flow rates designed to transfer heat (save energy). The tow fluids exchanging the heat and the amount of heat are critical to an efficient heat transfer process.

What does the cloud point of a substance determine?

Help to determine the temperature at which paraffin crystals will begin to block fuel filters and lines.

Lighter components normally have ___________ vapor pressure

Higher

Most of the time there is a _______ behind equipment failure

Human error

Describe the two major factors that determine whether a unit experiencing problems will attempt to keep running or shut down

Human life is at risk or plant equipment is at risk

Explain how steam heating of a blocked in heat exchanger full of a liquid can be hazardous?

If a pressure relief valve is not provided, liquids expand when heated. if a vessel is blocked in something is going to give

Why wouldn't you collet a sample from a dead leg in a piping system

If the line is not purged long enough to drain all the old materials in the line, the sample will have the same composition as the last sample taken from that point

Explain how an operator should stop a whipping hose?

Leave the area immediately and shut off flow to line. Never attempt to grab and restrain a whipping line or hose

6.Condensate is typically returned to the boiler for reuse.

True

Decrease pressure in tower?

Increases heat

Which are different types of start ups except

Initial maintenance start up emergency not emergency start up

Define a bad sample.

Is a sample that does not represent the true nature of the material being sampled.

Define confined space according to OSHA.

Is an enclosed area which is large enough to enable an employee to enter and perform assigned work, has limited or restricted means for entry or exit, and is not designed for continuous employee occupancy.

Write the definition of job aid.

Is essentially a memory jogger or short list.

Superheated Steam:

Is steam that contains more heat than what is required to maintain it above its dew point. If steams dew point 300 psia is 417.5 degrees F, any steam hotter than 417.5 degrees F is superheated

The air pressure for utility air is regulated

True

Process Diagrams

Process Diagrams can be broken down into two major categories: Process flow diagrams and Piping and Instrumentation dragons.

Name the OSHA standard concerned with abnormal situations

Process Safety Management

Symbols and diagrams can be broken down into 4 primary parts:

Process equipment symbols, process instrument symbols, process flow diagrams (PFDs), Piping and instrumentation drawings (P&IDs)

List five people who might be involved in a permit system?

Process technicians, process supervisor, maintenance supervisor, the person performing the work and safety permit inspector

List six types of emergencies

Process upset Terror attack or threat utility loss explosion injury-medical leaks fire

What do the intials PV stand for?

Process variable

Which of the following flare system components is a vessel designed to seperate liquid hydrocarbins from vapors being sent to the flare for buring?

Kockout drum

The most common gas detector used in process plant is?

LEL oxygen meter

A ______ of lubrication is the quickest way to shorten the life of moving equipment

Lack of

Discuss why steam system failures are not common

Large processing sites have two or more boilers

List four types of hazards associated with high pressure systems?

Leaks, pulsation, vibration, release of high pressure gases, and whiplash from broken high pressure tubing and hoses

Listening is what percent of communication?

Listening is 50% of any oral communication.

D Mr.(demister)

Located on top of the vessel it dries instrument air. it knocks out the moisture and drops it to the bottom because moisture in the pipes could corrode and can also freeze up pipes

List four types of energy isolation devices

Locks tags blinds chains double block and bleed

Word Problem

Look back at systems homework

How does a worker in any business get involved in quality?

Management train them in quality, they must train on the quality tools they will use to make incremental improvements. then management must encourage and demand employees use the tools

Common Pressure Indicators

Manometers, bourdon tubes, or helical, spiral, or bellows-shaped tubes.

MTBR means

Mean time between repair

Explain why electric motors must be megged

Measuring the electrical resistance between the amateur and field coils before attempting to start the motor can prevent shorting out the motor caused by the accumulation or condensation

The _____ is a time chart that identifies all key turnaround planning activities needed prior to execution

Milestone plan

Explain the two reasons why equipment deteriorates.

Minor defects are not being corrected and improper maintenance or the lack of.

Describe the job attendant (hole watch)?

Monitor the safety of the persons working in confined space. review the permit before entry and keep unauthorized personnel out of the area. ensure ventilation equipment is working and tend the lifeline of the entrant. monitor the CS workers and summon help if needed. they should have the authority to stop work if they detect a hazard

Are teams better than individual decisions

More diversity. One may be good mechanically minded, one may be a better writer, etc

What information is contained in the operator logbook?

Most logbooks are the written passed-down information for an area of responsibility and include all information pertinent to the safe and efficient operation of that area. Safety hazards, equipment problems, operational problems, and operational adjustments made during the shift are entered into the operator logbook.

Explain why steam purged vessels must be backfilled with fuel gas or any suitable gas?

Must be backed (pumped) into the vessel when purging is completed this is done to displace the steam which if left inside will condense and form a vacuum

Explain two reasons why equipment deteriorates

Natural deterioration due to aging, wear, heat and forced deterioration due to improper lubrication, choking, cavitation, dust, abrasives

Nitrogen is a blank gas

Nitrogen is an inert gas but can kill

When used as a backup nitrogen must be

Nitrogen must be announced or radio announced because it is and if it exceeds the Asian and can kill people even after just one breath

Describe how a process technician's role has changed in the last 30 years?

No longer confine themselves to just production work. They are actively involved in safely committees, health issues, quality concerns, public relations and environmental concerns.

Black smoke means

No steam on the flare

Utility air

Not dried

Before you start the unit make sure the flare is

On and it is the last thing when you close down the unit

Basin

On the bottom of the cooling tower sometimes does not look deep but can be his deepest and 12 feet there's a large amount of silt build up

Know none straight chain single bond hydrocarbon?

Paraffin

Flow (Continued)

Rotameters have a glass tube with a flow element trapped between the measurement grid Flow typically enters at the bottom of the rotameter and lifts its flow element Oval gear meters are turbine flow meters displace a specific amount of liquid on each rotation This is used to calculate total flow rate through the system

Explain why technician collect samples

Samples are collected to verify that all units streams are within specification

Interlocks and Permissives

Permissive- A special type of interlock that controls a set of conditions that must be satisfied before a piece of equipment can be started. - It deals with start up items, whereas hardwire interlocks deals with shutdown items. - This type of interlock will not necessarily shut down the equipment if one or more of its conditions are not met - It will however, keep the equipment from starting up

Latent Heat

Phase Change

Explain five factors that contribute to accidents during turnarounds

Piping and equipment opened, providing opportunities for flammable mixtures to form or for toxic materials to leak out

What are plant utilities?

Plant utilities provide services that are essential to the efficient operation of the facility. Utilities include systems such as water, steam, condensate, fuel, oil and gas, flares, and air.

A _______ is anything that might explain the abnormal situation

Potential cause

Which of the following does an expansion valve do in a refrigerant system?

Reduces the pressure of liquid refrigereant, causing it to cool

4. What does the term custody transfer mean when dealing with samples? Why is it important?

Refers to the transactions involving transporting physical substance from one operator to another. This includes the transferring of raw and refined petroleum. During custody transfer, accuracy is of great importance to both the company delivering the material and the eventual recipient, when transferring a material

To reduce flooding on a column you reduce

Reduce feed rate reduce reflux reduce temperature reduce bottoms flow you do not reduce bottoms flow

Primary tool used for investigations is

Root cause analysis

_____________ to test the pump without using process materials

Running in

The _______ is one of the most important prevention tools a technician has at his service

SPC (statistical process control) chart

The ____ prevents the valves on the truck and the material in the truck from being tampered with

Safety seal

In our survival experiment the least important item was

Salt tablets

List six benefits of an operator maintenance program

Significant drop in unplanned maintenance, emergencies and chronic failures Uninterrupted production, good quality output and less rejections Reduced catastrophic breakdowns Reliable and safe operations, high plant on-stream factor Reduced downtime during repairs because of timely maintenance Low maintenance, inventory and operating costs Reduced manpower requirement Enhanced knowledge and understanding of the equipment

Distillation has a series of __________?

Stills

Give two reasons why sulfur or sulfur compounds in finished product is a problem

Sulfur is corrosive and some sulfur compounds have a very disagreeable odor. Sulfur can add color, odor, or undesirable compounds during chemical reactions

Describe super heated steam.

Super heated steam is steam that is heated to a temperature that is above saturation temperature for its designated pressure.

Explain why tag out is used instead of the lockout procedure?

Tags should be used only in cases where a lock is not feasible

Explain the importance of those five roles to the process industry?

Technical expertise required to understand the functioning of a process unit and help keep it on spec. Regulatory knowledge to maintain regulatory compliance. Communications for efficiency and quality. Teamwork ensure cooperation and efficient operations.

Purpose of TCV-5 in the reactor drawing

The 3 way valve diverts the flow away from the feed heat exchanger

172.Steam traps are located throughout the system after each device where steam is used.

True

174.Return steam traps discharge condensate directly back to the boiler.

True

19.A package boiler is a self-contained unit that is preassembled at the factory.

True

198.A fuel oil relief valve is located between the fuel oil pump and the fuel oil discharge valve.

True

199.The fuel oil pump should be started with its discharge valve open.

True

200.Cold fuel oil in the tank will give a high suction reading.

True

202.Starting the fuel oil pump with its discharge valve closed causes the relief valve to open.

True

203.Fuel oil burners commonly use atomizing burners

True

Discuss how turnaround is evaluated

This evaluation should consider the goals of costs, timing, safety and unit performance after the turnaround

Short essay name three reasons for using LOTO

Three E's employees environment equipment minimize cost of injuries minimize cost of investigations

207.Secondary air is needed to bum the fuel oil efficiently

True

Explain why it is important to empower employees?

To make necessary organization changes, have responsibility, a sense of ownership, satisfaction in accomplishments and power over what and how things are done

Why is the loading arm lowered just inches off the bottom of a cargo tank

To prevent problems with static electricity, loading line is lowered straight down into the tank and stopped just off the bottom

What is the primary function of todays process technician?

To proactively manage their plants to maximize safety minimize environmental impact while driving the process to optimal production and profitability.

Explain the purpose of the hot work permit?

To protect personnel and equipment from explosion and fires that might occur from hot work performed in an operational area

Demister pads are found?

Top

Multiple-choice last thing before you give to maintenance on looking at a pump

Turn on the on off switch to make sure it is D energized

Short answer why is it good that we have good shift relief, Sharing of information

Unit continuity

Explain how a pressure gauge failure can injure a worker?

Unless the gauge case is equipped with a blowout back, the face of the gauge will rupture first, hurling out pieces of glass and metal. A person standing in front will be injured

List several departments outside of the unit about to startup that must be notified of the date of the startup

Utilities and raw material suppliers,Neighbor units should be notified also the safety department

explain the deference between utility air and instrument air.

Utility air is compressed air piped throughout the facility to power tools and equipment. Instrument air is used to operate all monitoring and controlling instruments in the piping facility.

What is a utility station?

Utility stations provide maintenance and operational personnel with a centralized location to find water, air, steam, and nitrogen.

Purpose of the reboiler

Vapor Maker

And say why are written record so important

Verbal instructions or records can be misunderstood also there is a record if it is written

_____introduces material into a process at a desire rate

Volumetric feeding

Explain the purpose of a technicians rounds

When a operator makes rounds he is surveying his area of responsibility. The purpose of the surveillance is to spot deviations from normal operations

3. Describe one way vacuums are created in a vessel.

When a vapor cools and liquefies, such as steam, this will decrease the pressure inside the vessel.

What type of tasks require written procedures?

When starting or stopping a piece of equipment or a unit. Any operation or task that could adversely affect safety, production, quality, or the environment if performed incorrectly.

FLAME FAILURE

When the flame in the furnace goes out.

CONVECTION

___A method of heat transfer that occurs as heat moves through a fluid

Name three different permits

Work called work confined space insulation

Explain the information a flash point test yields.

Yields information that informs the material is of the right standard to be used.

EPA gets mad if you have black smoke for how long

You cannot have black smoke for more than five minutes before EPA has been notified.

BUTTERFLY VALVE

___A balanced valve used to control gas flow to gas-fired boilers.

VACUUM

___A pressure below atmospheric pressure.

RANK

___Refers to how hard the coal is.

ENTHALPY

___Total heat in the steam.

transmitter

a device that receives its signal from the sensing element and transmit its signal to the controller or indicator

Nitrogen

an inert gas that is used to purge, or remove, explosive gases and air from process systems and equipment

near miss

an unsafe act that does not result in an incident or accident.

hot work

any fire or spark-producing operation (ex. welding, burning, riveting)

List three types of trailers used for transportation of bulk materials on highways

atmospheric pressure, low pressure, high pressure, corrosive, cryogenic, and tube trailers

Discuss how nonverbal communications aids in communication

body language, gestures, hand signals and alarms

Distillation towers separate mixtures based on ______

boiling point

The ______ is the weakest part of a compressed gas cylinder

brass cylinder valve

Explain why process focus is important to a technician?

can ensure that the processes that fall within their scope are documented, communicated, measured and continuously improved as time goes on

List the three reasons why level checks are important on a storage tanks

check for theft, malfunctioning gauges, leaks, and protection of transfer pumps

Name five water systems that can be found in a piping facility.

cooling water, boiler water, plant water, utility water, and emergency water.

List the plant auxiliary systems

cooling water, firewater, flare, refrigeration, lubrication and hot coil

list five physical test

distillation, vapor pressure, flash point, specific and API gravity, pH and viscosity

define physical test

does not change the chemical composition of the sample

Describe the hazards created when a sample is mislabeled

equipment may be damage or laboratory technicians injured by a physical or chemical hazard

List two reasons the steam trap failure

excessive backpressure, dirt and wiredrawn

What will protect the steam header piping from distorting or fracturing when it heats up?

expansion joints

definition of micro-insult

exposure to small or supposedly insignificant amounts of a harmful chemical

Explain why housekeeping is important to loading technicians

housekeeping minimizes health hazard. If a liquid spills onto the tank during a transfer, it should be cleaned off immediately to minimize the risk of individuals coming into contact with the tank later

Explain why some cargo tanks are treated as dedicated tanks

if the product is unusually hazardous, such as hydrocyanic acid, if the product can react with other materials or is the manufacturer wants to be sure that some other material left in a car a heel does not contaminate their product

stripping section

is the section of a distillation tower where the heavier components with higher boling points are located

Explain how lowering the exhaust pressure of a steam turbine affects efficiency

lowering the exhaust pressure increases the amount of work a turbine can do from a given amount of steam

List the four major steps of a material transfer

making preparations, lining up valves and initiating the transfer, monitoring the transfer and completing the transfer

What precautions must be taken when using detector tubes

moisture or particles affect their performance. although there is a guard section at the entrance t the tubes, moisture or particulate matter can quickly exceed the capacity of the guard section. detector tubes should not be used in a rainy, damp or dusty area

Before an electric motor is started, technicians should verify the _____ is free to rotate

motor shaft

Most liquid materials transported by rail are carried in ________

non pressurized or general service tank cars

The first most destructive lubricant contaminant is ______, the second is ________.

particles and water (moisture)

List four characteristics of bulk solids

particles size, density, flow ability, ability to be fluidized, and moisture content

List the plant utility systems

plant air, instrument air, nitrogen, natural gas, steam and electrical

List the two pneumatic systems

positive pressure and negative pressure

List two purposes of steam tracing

prevent plugging of lines and prevent freezing

List the three costs of quality?

prevention costs, appraisal cost and failure costs

Explain why flaring is a shutdown expense

product and materials are wasted to flare

List two reasons why technicians submit samples for viscosity test

product specifications purposes and troubleshooting contamination of a liquid by another liquid

Discuss some considerations involving the gas detectors and its operator involved in monitoring the atmosphere of confined space?

properly calibrated instruments, documented procedures, training on the detector and critical evaluation of results by a qualified person

Describe two common material flow problems

solids clinging to the interior of a vessel and solids forming blocks or restrictions at hopper outlets

lubrication system

that supplies oil or greases to equipment parts such as bearings, gearboxes, sleeve bearings and seals

270.A leak on the fuel oil suction line between the tank and the suction side of the fuel oil pump would result in__.

the suction gauge pulsating B. air entering the suction line C. pulsating of the fire in the boiler D. all of the above*

In some processes

the heat of the fluid is not sufficient before the fluid enters the tower, it must first go through s pre-heater.

overhead

the product stream that comes off the top of a fractionation tower

How are specific gravity tests helpful to a technician

they can indicate contaminated material and aid in identifying material

If instrument air is lost and a control valve failed closed, how would technicians rout flow through or past the control valve if they had to?

through a bypass system

List three ways flame impingement affects the economics of a furnace?

tube oxidation, product breakdown, reduced product flow rates, reduced production and shutdown for decoking

Explain why it is important that technicians understand the economics of their unit?

understand the business they are in, what affects the bottom line and why it is important to increase productivity

Explain what is meant by the term bumping a motor

working the start and stop buttons several times a minute

183.Condensate in the steam lines can result in__

D. water hammer

244.When burning No.6 fuel oil, the fuel oil strainers should be cleaned at least once every__hr.

D.24

302.__are pollution standards for six priority polletants set by the Environmental Protection Agency through the Clean Air Act

D.NAAQS

148.A__ pump returns condensate from the system back to the boiler.

D.vacuum

Name the federal agency that regulates the transportation of bulk materials on public highways

DOT Department of Transportation and ICC Interstate Commerce Commission

Describe several adverse outcomes that may occur due to a failure to clearly and precisely communicate information.

Dangerous situations, loss of profit, customer dissatisfaction, work stoppage, or bad feelings that result in divisiveness and workplace tensions.

13.Heat always flows from a material having a lower temperature to a material having a higher temperature

False

135.Centrifugal feedwater pumps are commonly driven by steam.

False

136.A check valve is opened by turning the handle counterclockwise.

False

The productivity of a process unit is dependent upon what four factors?

employee skills, talents, morale and initiative

The biggest expense associated with steam production is

energy fuel

what is the purpose of procedure validation?

ensures the procedure does what it is suppose to do. ensures accurate, complete and written so that the employee are willing and able to follow its instruction

Explain why a technician should understand the importance of pH results to her area of responsibility

environmental releases must meet compliance for pH values or the release may harm the environment. Certain substances are corrosive. They corrode piping and vessels, cause clotting of process materials, stop up drains and valves and may initiate unwanted dangerous chemical reactions

flares

environmentally-approved devices that burn waste gases collected from various process sources to reduce pressure

Name the two failure modes of control valves

fail open and fail close

The most hazardous time on a unit about to startup is when ______ is introduced into the unit

feedstock

List the five categories of samples

feedstock, finished product, process streams, auxiliary systems and utilities and environmental

List five pieces of safety equipment the outside technician should inspect

fire extinguisher, fire monitors, breathing air equipment, safety showers and eye wash stations, relief valves, fire blankets and unit fire hoses

List five reasons expenses of a unit shutdown

flaring of unit materials, off- specification products produced, additional manpower is required, loss of production. additional environmental compliance, increased accidents and injuries

List four type of steam traps

float, thermostatic, fixed orifice, thermodynamic, inverted bucket and bimetallic

Which if the following is NOT a hazard of compressed air?

freeze burn

Explain how excess air in a furnace wastes fuel?

fuel is wasted heating excess air that is dumped into the environment

Fuel gas

gas used as fuel in boilers and other types of furnances

Service (raw) water

general purpose water that may or may not have been treated

Few questions from start up from inside console 1 we know we are gonna get. When to put your control valves to put in automatic? What do we do before we put it in automatic?

get it in operating range.

Describe one lubrication

gravity use drip feeders, splash have an oil sumo or oil reservoir built into the equipment housing

How does a Cascade Loop work

"is a control scheme in which the output of one controller becomes the setpoint for another." (273) "reason for using one is better control and reduced lag time"(274) Source:Instrumentation book

2. The average fine for an EPA citation is:

$250,000.00

Programmable Logic Controller

- A programmable logic controller is a modern control system that combines microprocessor features with software-configurable controllers - This type of system require minimal space, is extremely reliable, is reprogrammable, and has a high computational ability - Another attractive feature is that laptop computers can interface with and program the system

Pressure

- A variety of instruments is used to measure and indicate pressure - Operators frequently walk through the unit and review various pressure gauges -Console operators closely monitor pressure variables and respond to any alarms - Pressure readings are typically measured in PSIA or PSIG

Final Control Element Common terminology for actuators include

- Air To Open: Spring to close-fails in the closed position if air system goes down. Air line is typically located on the bottom of the dome. - Air to Close: Spring to open fails in the open position if air system goes down. Air line is typically located at the top of the dome. - Double-acting, no spring-air lines located on both sides of the dome

Interlocks and Permissives

- An interlock is a device designed to prevent damage to equipment and personnel. -It accomplishes this by stopping or preventing the start of certain equipment functions unless a preset condition has been met. There are two types of interlocks: 1. Soft Wire 2. Hard Wire Hardwire interlocks can't be bypassed-they must be satisfied before the process they are part of can take place.

Controllers and Control Modes

- The primary purpose of a controller is to receive a signal from a transmitter, compare this signal to a set point, and adjust the process. -Controller comes in three basic designs: 1. Pneumatic - 90% Likely 2. Electronic 3. Electric

Tuning Controllers

- Turn rate action off - Set integral (reset) action to minimum - Establish arbitrary gain -Set controller to AUTO mode 1. Reduce gain if process mode 2. Increase gain if process response is too slow A graph of the process should be a straight line when the process is in control.

Final Control Element

- Final control elements are typically automated valves; however, motors or other electrical devices can be used - To automatic a valve, a device known as an actuator is installed - The actuator controls the position of the flow control element by moving and controlling the position of the valve stem

Process Variable and Control Loops

- Process Variables typically fall into five different groups: Pressure, Temperature, Flow, Level, Analytical Variables - Each control loop is specifically designed to work with a selected variable - Process technicians monitor many control process variables

Basic Elements Of A Control Loop

- Process technicians use instrumentation to control a variety of automated processes - The key component of automatic control is the control loop, a group of instruments that work together to control a process - These instruments typically include a transmitter coupled with a sensing device or primary element, a controller, a transducer, and a control valve (final control element)

Standardization of Process Symbols

- Some standardization of process symbols and diagrams is taking place, but the process tech must learn what symbols his or her employer uses - The symbols shown in this chapter reflect a wide variety of petrochemical and refinery operations

Final control Element

- The most common type of automated valve is a globe valve, because of its versatile, on/off or throttling feature - Control loops use on-off or throttling-type valves to regulate the flow of fluid in and out of the a system - Automatic valves can be used to control pressure, temperature, flow, or level

Condensate induced water hammer can produce pressure surges __ to ___ times greater then those caused by steam flow induced water hammer.

-10 to 100

Analytical

-Analytical Variables are associated with devices designed to measure the composition of a substance. - Other examples of analytical process variable include pH or parts per million - These variables are frequently tracked on a water cooling system - Plastic Plant Technicians check for melt flow, color, and concentration of special additives

What is the formula for calculating warmup condensate load for a system with automatic warm up?

-C=0.494 M (t₂−t₁)/ L Where; C= amount of condensate in kg 0.494=specific heat of steal pipe in kJ/kg °C M=total mass in piping t₂=final temp of pipe in °C t₁=initial temp of pipe in °C L= latent heat of steam + sensible heat-sensible heat at t₁ in kJ/kg C is than divided by the time in minutes required for warm up than multiplied by 60 to give the load in kg/h

Formula for calculating load for normal radiation loses?

-C=AU(t₁-t₂)E/L Where; C=condensate in kg/h A=external area of pipe in m² U= heat loss from uninsulated pipe in kJ/m²/°C temp. dif./h t₁=steam temp in °C t₂=air temp in °C L=latent heat of steam at operating pressure E= 1-effciency of insulation

Flow (Con't)

-Orifice plates are flat plates with holes that are typically smaller than the inside diameter of the pipe - The intent is to place the device between two flanges and restrict flow so that an artificial high-and-low pressure zone is created on each side of the orifice -A transmitter is used to calculate the differential and calculate a flow rate

What is the formulat for R-value?

-R-value=thickness/k-factor

What needs to be installed in the trap discharge line when the pressure in the discharge piping can exceed the pressure in the inlet piping?

-a check valve

How often should traps be dismantled for inspection? What other tasks should be done at this time?(3)

-at least once a year -examine body and parts for corrosion, wear, etc -internals cleaned or replaced as necessary -new gaskets

List the steps to be followed when commissioning a new steam trap (11).

-blow main steam header at full pressure , using low point drains to remove crude -close trap isolation valves -remove trap, install cap on line below strainer -fully open trap inlet -partially open strainer blowoff(ensure good volume of steam) -close trap inlet -remove cap, clean strainer -reassemble strainer -reinstall trap -crack trap inlet slowly to fill with condensate -open outlet

What are the variables that correct steam trap selection is dependant on? (6)

-capacity under start-up -capacity under normal operating conditions -temp. it will handle -steam header temp -∆p across trap during normal conditions -location of the tap (inside or out? freezing?)

Why should lifts be avoided in trap discharge lines? If a lift is used what kind of trap is most common? Why?

-causes water hammer -inverted bucket -can handle moderate water hammer

Basic operation of the controlled disc steam trap?

-condensate and air enter -pass through heating chamber -this flow lifts disc off inlet -condensate and air to outlet -when steam, increased velocity reduces pressure -pressure in control chamber above closes -always closes in the presence of steam

Steam trap installations considerations? (11)

-correct capacity and pressure rating -accessible location (close to and below drip point) -not backwards (check markings) -unions and isolations valves on either side -strainer *UP*steam -test valve, discharging to atmos., downstream -piping NOT smaller than trap -inlet slopes toward trap -if many traps drain to a common header, check valve between each trap and the return header -use self-draining traps where freezing can occur -each piece of equipment has its own trap

Advantages of the controlled disc trap? Disadvantages?

-disc is the only moving part -suited for SH steam -water hammer and vibration do not affect -low condensing capacity -will not operate at low pressures or at high back pressures

When List the key considerations that will help to maintain the integrity and maximize the life of insulation?(7)

-don't get it wet -should not be cracked or broken -don't remove cladding -don't walk on it -ensure all covers, boxes, and blankets in place -repair damaged insulation immediately -replace missing insulation ASAP

For a trap used to drain a steam main, when does the greatest rate of condensation occur?

-during the warmup period --after that the only condensate produced is due to normal radiation loses

Advantages of insulating blankets? Disadvantages?

-easy to install/remove -convenient for oddly shaped components -can be used in high temp applications -do not fit tightly∴ not used where external corrosion a concern

True OR false? A check valve is required if either the stop valve or the steam trap is designed to automatically prevent reverse flow and is capable of with standing a reverse differential pressure equal to the design pressure of the discharge piping.

-false, of course you don't need a check valve. you do need to actually read the question though dummy

True OR False? Drip lines from piping or equipment operating at different pressures can be connect to discharge through the same trap?

-false, the canNOT

Elastomeric? Temp. range? Advantages? k-value?

-foamed resin combined with elastomers -up to 104°C -good cutting characteristics -low water and vapour permeability cost efficient for low temps -high resiliency -fire retardent 0.040 @ 93.3°C

Foamed plastic? Temp. range? Advantages? Disadvantages? k-value?

-foaming plastic resin -negative 183 to 150°C -light weight -excellent moisture resistance -good cutting characteristics -fire retardant -λ decreases after initial use -0.037 @ 10°C

Glass fibre? Temp range? Ad? Dis? k-value?

-glass processed into fibres, then formed into covering sections -up to 454°C -noncombustible -water absorbent -0.032@ 23.9°C

What properties should a material used as insulation have?(6)

-high insulating value -long life -vermin proof -non-corrosive -retains shape and insulating value when wet -ease of application and installation

Expanded silica? aka? Advantages? Temp range? k-value?

-inert siliceous volcanic rock that has water added, then is heated to remove the water and expand the rock -Perlite -noncombustible -low shrinkage -high resistance to corrosion -med. to high -0.069 @ 93.3°C

What should all steam traps provide, no matter their principle of operation?(5)

-long life and dependable service -resistance to corrosion -efficient venting of air and CO₂ -be able to operate against back pressure in the return line -operate satisfactorily in the presence of scale or sediment

Describe the typical startup of a steam system. (13)

-low point drains open fully -crack bypass around main header inlet -if no bypass, crack main header inlet -check low point drains for condensate drainage -if no condensate, open bypass a little more -listen for water hammer, if heard reduce inlet opening -when dry steam from low point drains, close to just cracked until steam flow in main line -continue opening bypass to pressurize header -when bypass fully open and pressure steady crack main inlet, close bypass -continue opening main inlet -establish flow through header by putting steam users into service -close drains fully when flow established

What is calcium silicate pipe insulation? Temp range? Advantages? Disadvantages? Use? k-value?

-made of lime and silica, reinforced with organic and inorganic fibres and molded into rigid forms 38 to 650°C -good flexibility strength -can be dried without deterioration -noncombustible -water absorbent -primarily on hot piping -0.055 @ 93.3°C

Magnesia(85%)? Temp range? k-value?

-magnesium carbonate mixed with asbestos fibre -available molded or powdered -powdered can be mixed with water to form a cement -up to 320°C -from 0.35 to 0.42

How are half-cylindrical sections of pipe insulation held together? What are they then covered with?

-metal wires or bands -sheet metal, aluminum, or galvanized steel

Refractory fibre? Temp. range? Advantages? k-value?

-mineral or ceramic fibres, including alumina and silica, bound with high temp bonders -up to 1650°C -high thermal shock resistance -noncombustible -0.123 @ 538°C

Advantages of the ball float steam trap? Disadvantages?

-not affected by steam pressure changes -will not become air-locked in start-up because it readily discharges air immediately -float can be damaged by water hammer -air vent not suitable for use with SH steam -will freeze

When wrapping and cladding insulation what is the purpose of painting the linen covering? What is the purpose of the cladding? Where is this type of insulation most commonly used? What determines the material of the cladding? What type of cladding would be used in a chemical installation where there are caustic lines?

-paint provides a vapour barrier -protects against mechanical damage -protects against weather -reduces radiation losses -long lengths of pipe where there are no fittings or flanges -the environment -stainless

Mineral fibre? Temp range? Advantages? k-value?

-rock and/or slag fibres bonded together with heat resistant binder to produce fibre in a loose blanket, etc. -up to 1040°C -almost neutral pH -noncombustible -good sound control -0.040 @ 93.3°C

Reflective metal insulation? Advantage? Temp range? k-values?

-sheets of stainless spaced and baffled to form insulating air chambers -highly polished surface reflects heat and prevents heat loss due to radiation while absorbing very little by conduction -up to 1040°C -0.53 to 0.66

Advantages of the inverted bucket steam trap? Disadvantages?

-simple construction -easy to dismantle for inspection/cleaning -can be used with SH steam -can withstand water hammer better than float type -does not rapidly discharge air -can become air-locked at start-up -liable to freeze

In what way does trap capacity depend on pressure differential across the trap? What is the pressure differential across a trap?

-smaller differential = smaller trap capacity and vice-versa -difference in pressure between inlet and outlet

What considerations should be given for the proper installation and location of traps to prevent water hammer?(6)

-steam lines sloped toward drip trap station. -drip traps must be installed ahead of all steam regulator valves -each drain point equipped with drip pocket, free flow drain valve, and a trap -gate valves not installed with stems below horizontal to avoid condensate pooling -y strainers should have screen and dirt pocket horizontal -all equipment using a modulating steam regulator on the steam supply must provide gravity condensate drainage from the steam traps

What is an insulations R-Value? What is it's K-factor?

-the ability of a material to resist or restrict heat flow -a measure of it's ability to conduct heat (λ in academic supplement) ie coefficient of thermal conductivity

What must the condensate return system be capable of handling?

-the condensate load under normal operating conditions, without causing excessive back-pressure on the traps

Why is the bi-metallic steam trap only used for special applications?

-the movement of the strips is slight and the valve tends not to close tightly

If warm up draining is done automatically, how should the trap be sized? If manually?

-to handle the large amount of condensate produced during warm up -only big enough to handle condensate produced by normal radiation loses because the large volume of condensate can be removed by low point drains

What is the best way to avoid water hammer in a condensate return line?

-to have traps discharge to a gravity return line

Why is it usual to increase the calculated condensate load when sizing a trap?

-to provide a safety factor -ensure sufficient capacity in the event of a change in operating conditions

Disadvantages of a liquid expansion trap? When mounting, where should the outlet be?

-tube liable to corrode if condensate is corrosive -rod must be quite long to get enough movement (about 1m) -normally on the top -in cold climates, at the bottom for positive drainage

Insulating cement? Temp range? k-value?

-two types insulating and finishing -various insulating fibres and binders with water and cement -forms a plastic mass for use on irregular surfaces -can be applied to high temp surfaces -up to 1038°C -finishing or one-coat cements used in lower intermediate temp range -0.252 @ 316°C

Drain lines and traps must be provided at all points where condensate can accumulate, such as?(4)

-upstream of connection to a steam riser -at the ends of steam header mains -ahead of expansion joints and bends -inlets to steam valves

What is the basic principle of operation of an impulse type steam trap?

-uses the heat energy in steam and condensate to control it's operation -consists of a piston type valve within a control cylinder -some condensate goes out some goes to the top than out through a small hole in the centre of the piston valve -if condensate entering the top is at steam temp, it will flash into steam (because of lower pressure) and choke the hole

Basic principle of liquid expansion steam trap?

-uses thermostatic tube filled with special oil -air and condensate in -hotter condensate or steam enters, causes expansion of oil in tube -tube movement closes valve -once cool enough oil contracts, valve opens

For plants using steam at different pressures, where it is not feasible to run separate condensate return mains, how can the lower pressure/temp condensate be returned?

-using the heat exchanger method

What is the most positive way of determining if a trap is working properly? Three other methods?

-visually observe discharge from the trap using a test valve while the trap is in service -∆T, t₂ should be <t₁ -∆p -listening device ie stethoscope or ultrasonic device

Basic operating principle of the thermostatic steam trap? Advantages? Disadvantages?

-∆T of live steam and condensate -small, but can handle large amounts of condensate -can discharge large amounts of air during start-up -self-draining∴ does *NOT* freeze -corrugated element susceptible to water hammer or corrosion damage -cannot be used with SH steam (high pressure will ruin corrugated bellows)

What are some of the factors that determine the magnitude of water hammer shock?(3)

-∆T, the greater the dif. the bigger the hammer -dia. of pipe -amount of condensate in pipe (then more condensate, the greater the chance of trapping steam and the greater the cooling effect)

345.Priming and carryover can lead to water hammer and possible pipe rupture.

...

In general terms a 1C error in the temperature of most petroleum products will equate to an error of approximately _______ in the standard volume calculation

0.1%

Nitrogen has three purposes in the plant

1 blanket for keeping error away from product 2 back up air 3 purging or cleaning equipment

Why do we have a camera on the flare

1 make sure pilot light is lit 2 make sure flare is not smoking

A system is considered to be safe for opening when gas testing reveals that hydrocarbons are less than ____ of the vented purge system

1%

Describe the two major types of samples

1. Grab- Sample taken on a stream at a given time. 2. Composite- collected at sample point in a 24 hour period

List types of container used for sample collection

1. Clear glass wide mouth 2. clear or amber bottles 3. paint cans 4. sample bottles 5. bladders

Discuss three reasons why a technician would use a gas detector

1. Compliance to environment regulations 2. Detect fugitive emissions 3. Protect employee and contractor safety and health

Job duties prior to start up- Outside operator job duties

1. Drain is closed & plug 2. Good House keeping 3. Instrument air 4. Check line up 5. Turn on Fin-Fan 6. Exit route (Egress) 7. Check safety equipment

List the five categories of samples

1. Feedstock 2. Finished products 3. Process streams 4. Auxiliary systems and utilities 5. Environmental

List five hazards associated with collecting samples.

1. Mutagens 2. Teratogen 3. neurotoxins 4. Flammable 5. Corrosiveness

What 2 things can change the temperature in a active column

1. Pressure 2. Change in Composition

5 Primary Process Variables

1. Pressure 2. Temperature 3. Flow 4. Level 5. Analytical

Symbols and diagrams (4 primary parts)

1. Process Equipment Symbols 2. Process Instrument Symbols 3. Process Flow Diagrams (PFDs) 4. Piping and Instrumentation Drawings (P&ID)

List two reasons why technicians submit samples for a viscosity test.

1. Test Saybolt 2. Troubleshooting

List several reasons why you would collect samples from auxiliary and utility systems.

1. they can be the cause of unit problems 2. to eliminate cross contamination

Inside Operator Job Duties

1.Manual & zero all controllers 2. Check status on boiler for temp. & press. 3. Commission steam header 4. Establish circulation 5.Turn on Chiller 6. Turn on Vac. Compressor 7. Fire in the hole (put steam in reboiler) 8.monitor level of reflux 9. Turn on ovhd pump (operating range) 10. Open both valve FIC & LIC and put LIC on auto when in operating range 11. Unit line up & wait 20 mins 12. Wait for unit vol. displacement 13. Catch sample 14. Make adjustment to unit based on sample

purpose of E-101 in Reactor drawing 2 things

1.Only used for start up 2.End of run

To much feed in a column? list

1.flood 2.build up 3. D/P- differential pressure 4.Bottom level rising

Calculate the minimum/maximum operating range

15%-85%

The outage (vapor space) of a sample container should be what percent?

20%

The outage(vapor space) of a sample container should be about _____%

20%

What is the minimum distance a flare stack can be installed next to other pieces of equipment?

200'

Final Control Element Actuators

3 Basic Designs: 2. Electronically Operated - Solenoid valves are designed for on/off services When the wire coil is energized, a magnetic field is created, causing the armature to life and compressing the spring -The armature is held in place until the current stops - A motor driven actuator is attached to the stem of a valve by a set of gears

Final Control Element Actuators

3 Basic Designs: 3. Hydraulically Operated. - This type of actuator converts liquid pressure to mechanical energy - These are commonly used in combination with automated gate valves or slide valves, and are also used where a lot of stem travel is needed

1. How many work place injuries are reported each year in the United States?

3,800,000 injuries per year.

116.According to the ASME Code, a try lever test on safety valves should be performed every __ the boiler is in operation.

30 days

Listening is ____% of communication

50%

The percent of unplanned unit shutdowns due to human error is ______

63%

State the percentage of an electric motors total lifetime cost represented by electricity consumption

97.3%

279.__analysis is a chemical process used to determine the quantity of elements that a substance is composed of.

A.Ultimate

What is a meter run?

A meter run is a straight run of pipe that uses a set of orifice flanges to measure the rate of flow.

286.A pollutant is matter that contaminates __.

A.air B. soil C. water D. all of the above*

10. Explain how a distillation tests helps technicians troubleshoot a tower.

A printouts can be used to reveal data of the products. These analyses are entered into the laboratory's information management system that uploads into the processing unit. Process technicians access this information on their consoles and review it for indication of unit problems.

Electrical

A process technician typically traces power to the unit from a motor control center (MCC). The primary components of an electrical system are the MCC, motors, transformers, breakers, fuses, switch gears, starters, and switches. Specific safety rules apply to the operation of electrical systems. The primary safety system is the isolation of hazardous energy through lock-out/tag-out measures. Process technicians are required to have training in this area. Electrical lines are typically run in cable trays to switches, motors, ammeters, substations, and control rooms.

259.A(n) __ is an air pressure-activated switch that closes after proving sufficient pressure of combustion air from the forced draft fan.

A.air proving switch

Briefly explain how tag out of an energy source is done?

A tag out system is just like a lockout system except a tag is substituted for the lock

252.In a high pressure gas burner, the gas mixes with the air on the inside of the__.

A.burner

101.The water column is located at the NOWL of a low pressure steam boiler, so the lowest visible part of the gauge glass is __ above the lowest permissible water level recommended by the boiler manufacturer

A. 1"

37.__pressure is the pressure caused by the weight of air surrounding the earth.

A. Atmospheric

282.__combustion occurs when the fuel is not all burned, resulting in formation of soot and smoke.

A. Incomplete

330.__ draft is air that is pulled through the boiler.

A. Induced

185.__is jacketing material used to protect pipe insulation from mechanical damage

A. Lagging

29.__ combustion is combustion that occurs when fuel is burned using only the theoretical amount of air.

A. Perfect

326.Draft is the difference in pressure between two points that causes __ to flow.

A. air B. natural gas C. steam D. all of the above *

182.Steam traps remove__and__ from the steam lines

A. air: water

188.Steam strainers should be located on the steam line

A. before the steam trap

103. The boiler bottom blow down line should discharge to a __.

A. blowdown separator B. blowdown tank C. heat exchanger D. all of the above*

34.A__ boiler does not use tubes.

A. cast iron

97.A __ pressure gauge can read either vacuum or pressure.

A. compound

192.In a float thermostatic trap, the float rises to discharge__.

A. condensate

42.Heat is transferred by__.

A. conduction B. convection C. radiation D. all of the above*

21.__ is necessary to generate steam in a boiler

A. container B. Water C. Heat D. all of the above*

164.The low water fuel cutoff should be tested__.

A. daily

325.The amount of natural draft present can be affected by __.

A. dampers opened or closed B. temperature of the gases of combustion C. height of the chimney D. all of the above *

102. Blowback is the__ in the boiler after the safety valve has opened.

A. drop in pressure

117.The purpose of a safety valve is to prevent the pressure in the boiler from__.

A. exceeding the MAWP

23.A __boiler has heat and.gases of combustion that pass through tubes surrounded by water.

A. firetube

100.Safety valves are used on__ boilers

A. firetube B. watertube C. cast iron D. all of the above*

43.A(n) __ is a component directly attached to the boiler that is required for the operation of the boiler.

A. fitting

284.A__ is burner control equipment that monitors the burner start-up sequence and the main flame during normal operation

A. flame safeguard system

260.A combination burner allows the operator to switch fuels__

A. for economy B. if there is a shortage of fuel C. if there is a failure in the fuel system being used D. all of the above*

290.Combustion controls regulate__.

A. fuel supply in proportion to steam demand B. air supply C. ratio of air to the fuel supplied D. all of the above*

123.A__ is an auxiliary device commonly used with boilers to transfer heat from a hotter fluid to a cooler fluid.

A. heat exchanger

38.During operation, a boiler__.

A. holds water B. collects the steam that is produced C. transfers heat to the water to produce steam D. all of the above*

121.After the total force of the steam has lifted the safety valve off its seat, steam enters the __.

A. huddling chamber

125.A burner should always start up in __ fire and shut down in__ fire.

A. low; low

333.By using __ draft, higher rates of combustion can be achieved than with natural draft.

A. mechanical

335.Draft gauge measurements are expressed in inches of__.

A. mercury

179.When open, an os&y gate valve offers__ to the flow of steam.

A. no resistance

91.The only valve permitted between the safety valve and the boiler is the__ valve.

A. os&y gate B. os&y globe C. automatic nometum D. none of the above*

44.The nonflammable material used to insulate the outer surface of the boiler from heat is__

A. refractory

338.Improperly burned fuel results in__.

A. soot and smoke

120.The safety valve on a low pressure boiler is designed to open when pressure in the boiler exceeds

A. the safety valve setting

340.Too much draft when burning coal may cause

A. too hot a fire

161.Water is supplied to the condensate return tank by the __ pump

A. vacuum

288.__is the black residue formed when unburned coal in the combustion gases sticks to the boiler's tube surface.

A.Soot

What are the advantages and disadvantages of online analyzers?

Advantages: -Fast -Automatic upload -Rapid sample analysis Disadvantages: -High maintenance -Expensive

______ is one of the best insulators known which is why it is important to keep it out of steam system

Air

Pentane

C5H12

Cyclohexane

C6H12

Analytical

Analytical variables are associated with devices designed to measure the composition of a substance. Other examples of analytical process variables include pH or parts per million (ppm). These variables are frequently tracked on a cooling water system. Plastic plant technicians check for melt flow, color, and the concentration of special additives.

Describe the duties of the lead technician

Assign units jobs to technicians, schedules maintenance and product loading activities, holds shift meeting to relay information about unit operating changes and discuss accidents and incidents within the plant, and schedule overtime

92.The range of the pressure gauge should be__ times the MAWP of the boiler

B. 1 1/2 to 2

298.Well-designed burners firing gaseous and liquid fuels operate at excess air levels of approximately__%.

B. 15

87.The MAWP on a low pressure steam boiler is __psi.

B. 15

99. Safety valves are designed to pop open and stay open until there is a(n) __psi drop in pressure.

B. 2 to 4

255.__coal is hard coal.

B. Anthracite

281.__combustion is the bunting of all the fuel using the minimum amount of excess air.

B. Complete

30.__air is air supplied to a burner above the theoretical amount required to bum the fuel to ensure complete combustion.

B. Excess

331. __ draft is produced when air is pushed through the burner

B. Forced

289.__fire is burning the maximum amount of fuel in a given unit of time.

B. High

280.A(n) __system is a combustion control system that controls the amount of steam produced by starting and stopping the boiler.

B. ON/OFF control

291.__air controls the amount of fuel oil capable of being burned.

B. Primary

337.When measuring draft in the breeching, one leg of the tube is open to the breeching and the other to the

B. atmosphere

324.The induced draft fan is located in the__

B. breeching

274.In order to bank a fire, the__ is disengaged.

B. coal feed

301.The primary function of the boiler management and control system is __.

B. combustion safety

124.On an additive pressure control, __ pressure plus__ pressure equals __ pressure.

B. cut-in; differential; cut-out

32.The __ system provides the air necessary for combustion

B. draft

249.Fuel oil burners are designed to provide fuel oil to the furnace in a __.

B. fine spray

165.The burner should be _ when the low water fuel cutoff is blown down.

B. firing

112.When blowing down a boiler, the quick-opening valve should always be opened __and closed__.

B. first; last

266.The__ of fuel oil is the temperature at which fuel oil gives off vapor that flashes when exposed to an open flame.

B. flash point

Benzene

C6H6

Explain why technicians should not wear their field gear in lunch rooms.

Because the field gear will have contaminates on the gear and wearing the gear in the lunch room could transfer toxic materials to food or drinks, thus causing other technicians to get sick.

For a technician coming on shift, why is the first round so important?

Because they have a fresh set of eyes and senses not jaded by the 12-hour shift and having already made several rounds. On the technicians' first round they will be more alert and more critical of conditions.

Pressure Measuring Devices

Bellows, C-Type Bourdon Tube, Slack Diaphragm,Pressure Transmitter, Process Tubing

Give two reasons why some tanks have nitrogen blankets

Blanketing systems protect the tanks contents from air born contaminants and prevent the occurrence of a flammable mixture

What events happened that OSHA set up all these rules

Bo Paul India incident and the Phillips explosion

189.A(n) __is a device used to test steam trap function by analyzing the sound waves emitted.

D. ultrasonic tester

277.The ram-feed stoker is a(n) __stoker.

D. underfeed

88.Total force on a safety valve is equal to__.

C. area times pressure

31.The breaking up of fuel into small particles to maximize contact of fuel with air for combustion is__

C. atomization

180.Steam traps are__ devices.

C. automatic

341.Combination forced and induced draft is also known as__ draft

C. balanced

98.Vacuum is pressure__ pressure.

C. below atmospheric

106.To prevent air pressure from building up in the boiler when filling the boiler with water, the__ must be open.

C. boiler vent

107.To prevent a vacuum from forming when taking the boiler off-line, the__ must be open when pressure is still on the boiler.

C. boiler vent

153.The feedwater __valve opens and closes automatically.

C. check

248.A high vacuum on the fuel oil suction gauge normally indicates __.

C. cold fuel oil or a dirty strainer

264.A(n) __is a safety device that senses if the pilot light and/or main flame are lit.

C. flame scanner

275.In a screw-feed stoker, a(n) __draft fan supplies air for combustion

C. forced

111.The level of the water in the indicates the water level in the boiler.

C. gauge glass

114.A__ provides access inside the water side of the boiler for inspection, sight, or cleaning.

C. handhole

293.When the flame safeguard sequences the burner function,__ is the period of time during which the pilot and main burner must be lit.

C. ignition trials

160.The__shuts off the burner in the event of low water.

C. low water fuel cutoff

146.The water in a boiler is heated, turns to steam, and leaves the boiler through the __

C. main steam line

254.On a low pressure gas system, the manual reset cannot be opened until the__.

C. pilot is lit

265.The__ of fuel oil is the lowest temperature at which it will flow as a liquid.

C. pour point

108.The operating range of the boiler is controlled by the __.

C. pressure control

303.When an increase in steam pressure is required, the__ activates the programmer to start the firing cycle.

C. pressure control

285.A__ is a control that functions as the mastermind of the burner control system to control the firing cycle.

C. programmer

247. The __ valve protects the fuel lines and pump from excessive pressure.

C. relief

93.In most states,__ safety valves are permitted on steam boilers.

C. spring-loaded pop-off

35.To increase efficiency of the boiler, __.

C. the heating surface is increased

263.A(n) _sensor senses light frequencies that are higher than those visible to the eye.

C. ultraviolet

190.When an os&y valve is open, the stem is in the__ position

C. up

253.A __ is a narrowed portion of a tube.

C. venturi

296.A photocell sensor senses __light.

C. visible

177.Gate valves should always be __ or__ closed.

C. wide open; partly

33.The_ is the highest pressure in pounds per square inch at which a boiler can safely be operated.

C.MAWP

257.__ coal is coal that is ground to a fine powder

C.Pulverized

Acetylene

C2H2

Butane

C4H10

Explain the hazards created when a sample is mislabeled.

Can cause hazards because it will expose employee's to fire, explosions, and harmful contaminations in pipeline.

Equipment stoppage is termed as ________breakdown

Catastrophic

If the reactor is hot it

Closes the feed control valve and opens the Motor Operated Valve (MOV) to flare

Piping and Instrumentation drawing (PI&D)

Complex representation of the various units found in a plant. A P&ID is a road map, can show intricate details of a unit that cannot easily be noticed during a walk-through. Process technicians are expected to be able to read simple flow diagrams within hours of starting their initial training. Technicians will graduate to reading and using complex P&IDs over the course of their training.

272.Foreign matter in the coal hopper of the screw-feed stoker is best removed by__.

D. using the cutoff gate at the bottom of the hopper

268.The internal resistance of fuel oil to flow is the__.

D. viscosity

Compressor Symbols/Pump Symbols

Compressors and pumps share a common set of operating principles. The dynamic and positive displacement families share common categories. The symbols for compressors may closely resemble those for pumps. In most cases, the symbol is slightly larger in the compressor symbol file.

Describe one way vacuums are created in vessels?

Condensation of vapors in closed vessels, such as storage tanks is a source of vacuum pressure which could collapse the vessels.

Operating procedures manual:

Contains detailed instructions for properly operating the unit. It will include start-up, shutdown, and emergency procedures, plus normal operating procedures. It may also include safety information. A copy of this manual should be available in the control room. Several OSHA standards require accurate and up-to-date operating procedures.

89.The ASME Code states that boilers with over__ square feet of heating surface must have two or more safety valves.

D. 500

41.The amount of energy required to raise the temperature of 1 lb of water 1 °F is 1__

D. Btu

40.__ boilers have sections that can be assembled on-site to produce the boiler capacity required.

D. Cast iron

113.__ added to boiler water change(s) scale-forming salts into a nonadhering sludge.

D. Chemicals

181.__ allow movement caused from the heating and cooling of steam lines.

D. Expansion bends

300.__is the condition where a flame travels upwind and into the burner assembly

D. Flashback

45.__ is pure steam at a temperature that corresponds to the boiling point of water at a specific pressure.

D. Saturated steam

250.The rotary cup burner uses__ to atomize the fuel oil.

D. a spinning cup and high-velocity air

154.The vacuum pump pumps water and discharges air to the __.

D. atmosphere

178.All boilers in battery must have two main steam stop valves or one main steam stop valve and one__.

D. automatic nonreturn valve

186.Condensate from a nonreturn steam trap is pumped from the condensate return tank to the

D. boiler

26.Sensible heat is heat that__.

D. can be measured with a thermometer

278.A(n) __ system is a solid-state control system in which a building automation controller is wired directly to control devices.

D. direct digital control (DDC)

115.A(n) __gauge is a pressure gauge that reads more pressure than is actually in the boiler.

D. fast

152.A __may be required on some boilers to remove oxygen and other gases

D. feedwater heater

163.The__maintains a constant water level in the boiler.

D. feedwater regulator

36.The four systems necessary to operate a boiler are __, __,__, and__.

D. feedwater; fuel; draft; steam

109.The __regulates the firing rate between high and low fire of the burner.

D. modulating pressure control

334.Cold outside air affects the amount of __ draft produced.

D. natural

299.The __ of a modulating burner is the ratio of the maximum firing rate to the minimum firing rate.

D. turndown ratio

Explain the importance of environmental compliance to the process industries?

Failure to adhere to environmental compliance may result in fines or imprisonment

Why are fall and spring chosen as turnaround seasons

Fall and spring are the traditional seasons because this avoids shutting down production during the height of the summer gasoline seasons

128.The check valve on the feedwater line should be located closest to the shell of the boiler.

False

Analytical Variables

Examples: pH, Viscosity, Solids, Color, Freeze Point, Conductivity, Concentration, Acidity, Solubility, Turbidity, Oxygen Content, Percent Water

List five causes of equipment failure:

Failure Fault Faulty Design Manufacturer Faulty Selection Technical Division Faulty Installation Contractor or Maintenance Misalignment Maintenance Excessive Heat Operations

Orifice Plates

Flat plates with holes that are typically smaller than the inside diameter of the pipe. The intent is to place the device between two flanges and restrict flow so that an artificial high- and low-pressure zone is created on each side of the orifice.

Flow

Flow Rate is typically measured in gallons per minute (gpm) or gallons per hour (gph)

Flow

Flow Rate is typically measured in gallons per minute or gallons per hour

Primary Element / Sensor

Flow: Orifice Plate, Flow Nozzle, P Cell diaphragm. Sensor: P Cell Level: Float, Displacer, P cell (Diaphragm). Sensor: P Cell Pressure: Helix, Spiral, Bellows, Bourdon Tube, P Cell. Sensor: P Cell Temperature: Capillary Tubing, Thermal & Resistance Bulb. Sensor: Thermocouple, RTD Operators just need sensing device to work

131.A condensate return tank collects condensate returned from heating units for use in the boiler.

True

12. What is a GC? How is it used?

GAS Chromatography: Is a very complex subject that, due to time constraints, will be treated lightly and it is one of the most common of on-line analyzers on processing units. It separates a mixture, the separation allows identification and quantification of individual components of a mixture.

2. What is the difference between grab and composite samples? Why do we need both?

Grab Samples: Is a sample collected form a sample point that represents the sample in that stream at that time. Composite Samples: Is a collection of samples from the same sample point over a period of time (24 hours) mixed together in one container to make a composite that represents the material in that vessel or line.

Describe two major types of samples

Grab sample is simply a sample collected from a sample point that represents the sample in that stream at that time. Composite Sample is a collection of samples from the same sample point over a period of time mixed together in one container to make a composite that represents the material in that vessel or line over that time period

Elevation drawings

Graphical representations that show the location of process equipment in relation to existing structures and ground level. In a multistory structure, the elevation drawing provides the technician with information about equipment operation and location. The drawing closely resembles a process removes the outside wall of the building and draws the exposed equipment. This information is important for making rounds, doing equipment checks, developing checklists, catching samples, and performing start-ups and shutdowns.

_____maintains a set feed rate by weight per unit of time, such as pounds per hour

Gravimetric feeder

In the movie China syndrome what did The operator do wrong

He did not follow procedures

132.A globe valve used as a feedwater stop valve must be installed so inlet pressure is applied from under the valve disc.

True

What is a steam trap?

Steam traps are placed at pocketed low points and at the dead ends of steam headers to collect condensate.

133.The stop valve on the feedwater line should be located closest to the boiler.

True

134.The vacuum pump is designed to discharge air and pump water

True

137.A low water fuel cutoff is located slightly below the NOWL.

True

Electrical Drawing

Includes symbols and diagrams that depict an electrical process system. Electrical drawings show unit electricians where power transmission lines run and places where it is stepped down or up for operational purposes. A complex P&ID is designed to be used by a variety of crafts. The primary suers of the document after plant start-up are process technicians, instrument and electrical, mechanical, safety, and engineering.

Phases in the life of a plant

Initial normal shut down initial shutdown not initial shut down

Explain the responsibilities of the process technicians involved in a hot work permit?

Inspects the area and ensures housekeeping, blinds, isolates, and clears equipment, vessels, tanks and piping, immobilizes power driven equipment(lock out/tag out) determines PPE required and fills out permit and posts it at the job site

Latent heat:

Is the heat required for a phase change. It is the heat needed to convert ice into water or water into steam.

British thermal unit:

Is the most common expression of heat in the processing industries. Is the amount of heat that will increase the temperature of one pound of water by 18 degrees Fahrenheit. It would take 1 BTU to increase the temperature of one pound of water from 508F to 518F.

Specific heat:

Is the quantity of heat required to increase the temperature of one pound of a substance by 1 degree F. Different substances heat up at different rates. A substance that requires a small amount of heat to raise its temperature 1 degree F has a low specific heat. And the opposite for a substance that requires a large amount of heat has high specific heat.

138.The range of pressure on the vacuum switch on a vacuum pump is usually 2" to 8".

True

How does operating under positive pressure affect a furnace?

It can cause damage to the furnace roof or walls

How does bumping a motor harm the motor

It can over heat and damage it

List several ways the ability to improve reliability has a direct impact on bottom line costs

It increases mean time between repair, reduces maintenance costs, reduces equipment acquisition costs, reduces unit down time, reduces purchasing and inventory activities and reduces the production of off spec product

What Is wrong with dumping condensate to grade

It is a waste of valuable resource and heat energy

Audit

It is proactive before something happens keeps things from happening

Investigation

It is reactive after an accident

As a question concerning logbooks what are we having

It's good communication from shift to shift

14.Latent heat is heat identified by a change of state and no temperature change of the substance.

True

140.Any loss of water in the system must be made up by the makeup water feeder.

True

Positive Displacement Pump Symbol

Looks like a set of stairs, this illustrates how pressure builds on each rotation or stroke of the flow elements. Positive displacement pumps can be classified as rotary or reciprocating. Special symbols are used to describe each of these devices including screw pumps, gear pumps, and reciprocating pumps.

141.The boiler operator must be present during an evaporation test.

True

Describe how a process unit would detect the level of water in its lubricant

Most of the time, lube oil samples are submitted to the site quality control laboratory for moisture analysis. A new technology has been introduced for user level moisture detection in the form of a probe and a handheld data collector

Explain why quality is not the responsibility of the quality department or quality team?

Most plants don't have quality department b/c they cant afford. One or two quality leaders cannot make quality happen, it is up to the dozens or hundreds of workers in the plant

Explain why cleaning and ventilation is important to electric motors

Motors should be kept clean because oil and grease on motor windings can collect dirt that will restrict circulation of air through the motor. If the cooling air is blocked, the winding may get too hot

Instrument air

Must be dried and clean of debris ( instrument airlines are very small no bigger than the tip of the finger so there cannot be any debris in there)

143.Most makeup water contains some scale-forming salts

True

144.The function of the automatic makeup water feeder is to replace water that has been lost.

True

145.The automatic city water makeup water feeder is located slightly below the NOWL

True

15.Conduction is heat transfer that occurs when molecules in a material are heated and the heat is passed from molecule to molecule through the material.

True

Flow Measurement Devices

Orifice plates, venturi nozzles, nutating disc meters, turbine flow meters, oval gear meters, rotameters, pilot tubes, weird and flume, and flow transmitters.

Describe the course of action a technician should take when laboratory or analyzer data reveals out of range data.

Out of range data will be flagged, and the proper action is to view that section of the unit on their screen and check the SOCs of the equipment and streams. If they look normal, they should radio an outside technician and ask if they are aware of any problems in this area. Next, they would question if the outside technician noticed anything unusual about the sample that yielded the bad results. Lastly, to be on the safe side and to satisfy the International Organization for Standardization requirements, the inside technicians will request the outside technician to catch another sample and submit it for analysis. Often bad results are because of a bad sample.

Describe some of the knowledge an outside technician should have regarding his safety and health duties.

Outside technicians should be familiar with safety and environmental procedures and regulations that apply to their unit. They should know the hazards of the process materials.

8. What is the difference between physical and chemical tests?

Physical test: An analytical test that does not affect the chemical structure of a substance. Chemical test: An analytical test that destroys or changes the chemical structure of the substance being sampled.

For operator duties during maintenance

Prepare equipment for shutdown LOTO Write permits prepare equipment for start up

Last thing you should ever change on a column is

Pressure is the last thing you should ever change in a column

Purpose of improvement of data

Pressure of pumps discharge and suctions: Main Pressure in vessels: Feed pump: 31-32 psi Bottoms: 85 psi Reflux: -27 Boiler: 125-135 psi Tower: -27

Essay explain flow purging versus pressure purging

Pressure purging is done three times to get rid of all the chemicals for flow purging there is a slight nitrogen flow through the vessel

________ is a procedure in which an inert gas is used to remove undesired gases from a vessel to reduce the undesirable gas to a safe or acceptable level

Purge

Temperature Measurement Devices

RTD, Thermocouple, Bimetallic, Capillary Tubing

17.The ASME Code governs boiler design, material, method of construction, inspection, and quality assurance

True

Which of the following is NOT part of a hot oil system

Refrigerant

Explain why technicians collect samples.

Samples are collected to verify that all unit streams are within specification.

Equipment Location Drawings

Show the exact floor plan location of equipment in relationship to the plant's physical boundaries. Location drawings provide benefits similar to those of elevation drawings. The entire P&ID provides a 3-D look at the unit.

Flow Diagram

Simplified illustration that uses process symbols to describe the primary flow path through a unit.

Describe how a process technician plays a role in security?

Site workers are a production sites first line of defense. They monitor the site fence line when making rounds, know who should or shouldn't be in unit area, and recognize when anything in their area of responsibility is not normal

How do you find a leak

Soapy water

170.A steam header is a distribution pipe that supplies steam to the branch lines.

True

197.The fire point temperature is higher than the flash point temperature.

True

Piping Symbols

Some of the devices used in piping are strainers, filters, flanges, spool pieces, and steam traps.

Pumps and Tank Symbols

Some of these designs include centrifugal and positive displacement pumps. Centrifugal pumps can be mounted vertically and horizontally in the field.

Explain the danger of electrical sparks to the processing industry?

Sparks may ignite mixtures of air and flammable gases or vapors resulting in explosion and fires

Permissive Interlock

Special type of interlock that controls a set of conditions that must be satisfied before a piece of equipment can be started. Permissive deal with start up items, whereas hard wire interlocks deal with shutdown time. A permissive is an interlock controlled by the distributive control system (DCS). This type of interlock will not necessarily shut down the equipment if one or more of its conditions are not met. It will, however, keep the equipment from starting up.

Liquid weighs more than water because?

Specific Gravity

A _____ surrounds the man way to contain any spilled product.

Spill dam

______ is the critical placement of all the materials listed in the next sentence

Staging

Multiple-choice there are many operation procedures for

Start up normal operations lockout tag out overtime assignments overtime assignment is not the correct answer

Explain the function of steam traps

Steam traps are automatic valves that release condensed steam from a steam space while preventing the loss of live steam. They also remove air and non condensable from the steam space

Which of the following is NOT a key process variable?.

Surface area

_____ are workers who operate locomotives or railcar movers and move railcar about within the plant

Switch personnel

List five roles of a process technician today?

Technical expertise, regulatory knowledge, communications, problem solving and teamwork

205.Rotary cup burners atomize fuel oil using a spinning cup and high-velocity air.

True

206.Air used to atomize fuel oil is primary air.

True

Pilot

The _____ of the ignition source for lighting the flare, located at the flare tip

Heat of vaporization

The amount of heat required to convert a unit mass of a liquid at its boiling point into vapor without an increase in temperature.

Heat of fusion:

The amount of latent heat required to fuse a substance. One pound of ice at 32 degrees must gain 144 BTU of heat to fuse into water.

Describe the responsibility of the attendant (hole watch).

The attendant has the responsibility of monitoring the safety of the persons working in the confined space. They review the permit before any entry and keep unauthorized personnel out of the area. And ensures ventilation equipment is working, monitors the atmosphere in the confined space, maintains constant communication with the workers in the CS, and tends to the lifeline of the entrants. The attendant does not perform any rescue function and should not enter the CS in the event of a problem.

What is the function of a control valve manifold?

The control valve manifold is a series of valves and fittings that make use of an automatic valve to control and monitor the flow of commodity through the pipe.

Sensible heat:

The heat which increases the temperature of a substance but do not change its phase/state is called sensible heat

The higher the pressure of the steam

The higher the temperature. 900 pound steam is about 900° 400 pound steam is about 700° and 50 pounds steam is about 300°

What information is contained in the daily operating instructions?

The instructions include information that technicians need to know about product scheduling, daily operating objectives or targets, special operating instructions, maintenance schedules, etc.

Define Flashpoint

The minimum temperature at which a liquid will give off enough vapor to form a flammable mixture.

The most important item in our survival experiment was

The mirror

Explain the function of each end of a figure eight blind

The solid end prevent flow, the cut out end allows flow

Explain what the outside technician should do when maintenance informs them that their equipment is repaired.

The technician will briefly put the repaired equipment in operation and verify the equipment operates normally.

Dew point:

The temperature at which the water vapor contained in a volume of air at a given atmospheric pressure reaches saturation and condenses to form dew

Explain one way to determine if steam purging has removed all air from a vessel?

The temperature of a saturated steam air mixture at any pressure is an indication of its air content. There are tables that can be consulted that indicate the temperature and corresponding volume per cent air

209.The air atomizing burner uses air to mix with the fuel oil to achieve a high degree of atomization.

True

Briefly describe the duties of the lead technician.

Their duties are to do payroll, planning, scheduling, and preparing bills of laden or certificates of analysis, technician duties.

What would a noticeable change in control valve position indicate to a technician?

There is a change happening in the process. The valve is either opening to allow more process flow through or the valve is closing to allow less process flow through.

What is the hazard associated with collecting a liquid full sample cylinder of propane?

Thermal expansion may cause the cylinder to rupture

210.Complete combustion is achieved in a burner by supplying the proper mixture of air and fuel to the furnace.

True

Symbols and Diagrams

These process symbols form the written flow language necessary for understanding how a specific process operates

211.In a rotary cup burner, the solenoid valve controls the flow of fuel through the fuel tube.

True

Briefly describe the duties of the outside technician.

They are responsible for ongoing operation, maintenance, and security and safety of their areas of responsibility.

Briefly describe the duties of the inside technician.

They are responsible for the operation and control of the entire process unit form the board screen (console) in the control room and making adjustments as needed.

Instrument air and utility air

They are used in plants

Why is the process technicians most responsible for making quality happen in their process unit?

They understand the system intimately because they put in 40 hours a week in the system year after year

Heat Exchangers

They won't call them heat exchangers in the field. The will refer to them as their function. A heat exchanger is a device used to transfer heat energy between two process flows. The downward direction indicates heating.

What is the purpose of a technician making rounds?

This activity keeps the technician aware of the equipment and conditions in their area of responsibility.

212.Fuel oil to be removed from the burner nozzle is purged with air.

True

214.In a low pressure gas system, before the manual reset valve can be opened, the pilot must be lit.

True

217.Fuel oil is a liquid fossil fuel.

True

218.Plant flexibility is increased with the use of a combination burner.

True

219.Anthracite coal is hard coal

True

221.Bituminous coal is soft coal.

True

222.Boilers burning soft coal need large furnace volumes to complete combustion.

True

Discuss the importance of employee safety to the process industries?

Trained employees are valuable assets. If become injured must be replaced with overtime, their expertise is lost plus their injury might initiate an OSHA investigation

Explain why it is important that a flare system be operational before the process are bought into the unit

This mandated by law

__________ for shutdowns and startups is critical to avoid accidents and incidents

Training

10.Heat is generated in a boiler by the combustion of a fuel such as gas, fuel oil, or coal.

True

11.An internal furnace is a furnace in a boiler that is surrounded by heating surface.

True

12.Feedwater is water that is treated for use in a boiler.

True

127.A low water level condition in the boiler can result in damage to boiler heating surfaces.

True

129.The check valve allows the flow of water in one direction only

True

130.The check valve on the feedwater line commonly has a valve disc that swings to open and close the valve.

True

If the feed line has a small amount of bottoms where do you feed it?

Top

Process Flow Diagrams

Typically include the major equipment and piping path the process takes through the unit

List two hazards of water in a process unit?

Water can flash to steam and create high pressure, contain air and cause tank foam overs

Explain the harmful effects of water on lubricants

Water promotes several harmful chemical reaction that attack rust inhibitors, viscosity improvers, and the oils base stock. The effects are undesirable by- products such as varnish, sludge, organic and inorganic acids, surface deposit and lubricant thickening. Large amounts if emulsified water can lower viscosity and reduce lubricants load carrying ability

Foundation Drawings

Used by the construction crew pouring the footers, beams, and foundation. Concrete and steel specifications are designed to support equipment, integrate underground piping, and provide support for exterior and interior walls. Foundation drawings are typically not used by process technician; however they are useful when questions arise about piping that disappears under the ground and when new equipment is added.

Rotameters

Used in flow. They have a glass tube with a flow element trapped between the measurement drug. This type of device provides direct contact between the measurement element and the fluid. Flow typically enters at the bottom of the rotameter and lifts the flow element. Oval gear meters and turbine flow meters displace a specific amount of liquid on each rotation. This is used to calculate total flow rate through the system.

Process Flow Diagrams (PFDs)

Used to outline or explain the complex flows, equipment instrumentation, electronics, elevations, footings, and foundations that exist in a process unit. Process flow diagrams typically include the major equipment and piping path the process takes through the unit. Some standardization of process symbols and diagrams is taking place, but the process technician must learn what symbols his or her employer uses.

What is the purpose of procedure validation?

Validation ensures that procedure does what it is supposed to do, it is accurate, complete, and written so that employees are willing and able to follow its instructions.

Explain how an increase or decrease in temperature affects vapor pressure.

When the temperature of a liquid is increased, the rate of evaporation becomes temporarily greater than the rate of condensation but eventually the liquid and the vapor establish a new equilibrium point for this higher temperature. The gas molecules (vapor) moving inside the container exert a force on the sides of the container and on the liquid below. (Vapor pressure)

ORSAT ANALYZER

___A flue gas analyzer that measures the percentage of carbon dioxide, oxygen and carbon monoxide in the gases of combustion.

ULTRAVIOLET

___A form of light that is produced during combustion

PNEUMERCATOR

___A fuel oil level indicating device that gives a direct reading in gallons

FLASH ECONOMIZER

___A heat recovery system used to reclaim the heat from the boiler blowdown water and used in conjunction with the continuous blowdown system.

GAS COCK

___A manual quick-closing shutoff valve.

CONDUCTIVITY

___A measure of the ability of electrons to flow through a solution

Multiple-choice After emergency shutdown

You don't start up right away

WATER HAMMER

___A banging condition that is caused by steam and water mixing in a steam line.

HYDROGEN

___A basic element present in gas, coal and fuel oil.

ELEMENT

___A basic substance consisting of atoms.

INTEGRATOR

___A calculating device used on differential-pressure flow meters to determine hourly or daily flow rates.

DRY PIPE SEPARATOR

___A closed pipe perforated at the top with drain holes on the bottom that remove moisture from the steam.

STEAM BOILER

___A closed pressure vessel in which water is converted to steam by the application of heat.

UNDERFEED STOKER

___A coal-firing system that introduces the coal under the fire.

SULFUR

___A combustible element found in coal and fuel oil.

NATURAL GAS

___A combustible gas found in pockets trapped underground that consists mainly of methane.

MICROPROCESSOR

___A computer acting as a flame-monitoring device that programs the burner, blower motor, ignition and fuel valves to provide for safe burner operation.

VENTURI

___A constricting device used in pipelines to measure flow.

LIMIT CONTROL

___A control switch that shuts off the fuel when temperature or pressure exceeds the normal operating control setting.

POSITIONING CONTROLLER

___A control that regulates air and fuel going to a boiler furnace.

CHAIN (TRAVELING) GRATE STOKER

___A cross-feed stoker that is used with larger capacity boilers because of its ability to feed coal at a faster rate than other stokers.

BOILER ROOM LOG

___A data sheet used to record pressures, temperatures and other operating conditions of a boiler on a continuous basis.

LOW WATER FUEL CUTOFF

___A device located a little below the NOWL that shuts off the boiler burner in the event of low water, preventing burning out of tubes and possible boiler explosion.

OIL SEPARATOR

___A device that removes oil from the exhaust steam before it enters the open feedwater heater.

SCOTCH MARINE BOILER

___A fire tube boiler with an internal furnace.

What would a noticeable change in control valve position indicate to a technician

a change in control valve position could be an indication of improper flow rates, leaking instruments air system or unusual wear of the valve trim

Control loop

a collection of instruments that work together in a system to monitor and control a process

Distrubuted control system DCS

a computer based system that is used to monitor and control a process

annunciator

a device that displays alarm conditions through the use of flashing and continuously lit panels

Filter

a device that removes contaminants from lubricant circulating through a system

flare system

a device used to burn unwanted process gases before they are released into the atmoshpere

Packed tower

a distillation column that is filled with specialized packing material instead of trays.

refrigerant

a fluid with low boling point circulated throughout a refrigeration system

indicator device

a generic term for a type of equipment that indicates process variables; may be viaual (ex. light), audible (ex. horn) or both

List two criteria that necessitates a permit required confined space

a hazardous atmosphere and possibility of engulfment

Pre heater

a heat exchanger that warms the liquid before it enters the tower.

job safety analysis (JSA)

a method of analyzing how a job is performed in order to identify and correct undesirable conditions

Process variable

a operational condition that is associated or goes with a chemical processing operation such as temp, pressure, flow rate, level and compostion

flare header

a pipe system that connects several vents to the flare system

alarm

a signal that indicates the existence of an unusual or potentially hazardous situation

hot oil system

a system that heats heavy oils as a fuel source for furnances, boilers, reboilers, and exchangers

redundant system

a system that provides a backup in the event the primary system fails.

receiver

a tank that stores the liquid phase refrigerant once it leaves the condenser

interlock

a typed of hardware or software that does not allow an action to occur if certain conditions are not met.

Control valve

a valve that automatically controls the increase or decrease of fluid flow through a pipe by remote operation

knockout drum

a vessel located between the flare header and the flare system

An ______ is any unit upset or event that requires immediate action to prevent serious consequences to people, equipment or environment

abnormal situation

How much does water expand at its boiling point and normal atmospheric pressure?

about 1600 times in volume

Steam purging accomplishes what four objectives

air removal, evaporating trapped water, removing hydrocarbon liquids and gases and revealing plugged drains and vents

process fluids

any material that flows; it can be either liquid or gas. When under pressure, both gases and liquids transmit force equally. Process gases are compressible and liquids are not.

heavy ends

are substances that boil at the highest temperature.

light ends

are the materials in a distillation column that boil at the lowest temp.

Different systems

are used to distribute the water and make sure that it is in the proper form

First Law of Distillation

at constant pressure, composition sets the boiling point-(which sets the temp)

How are specific gravity tests helpful to a technician?

because it allows the producer to price out material by pound.

Why wouldn't you collect a sample from a dead leg in a piping system?

because sample will read the same as the last, due to remnant material left in the line

Explain why technicians is critical to the MTBR for pumps

because they operate and monitor the rotating equipment 24 hours a day 365 a year

List the types of valves found on a cargo trailer

bleed valves, vent valves, product outlet valves, and safety valves

How can you be sure all unit blinds are removed before startup

blind list

Describe the two dangers of an arc flash?

blindness, high temperatures and high pressure wave

List four types of permits?

confines space, hot work, lock out/tag out, cold work, critical lifts

Explain how technicians are more involved with predictive maintenance

by making rounds with a portable data acquisition terminal with the special programs for rotating equipment. They will collect data from rotating equipment and upload it to a control room computer where the unit engineers will access it and determine the running condition of the equipment

Explain why test for color are important

color provides and indication of contamination. the development of color in a product can usually be associated with low or poor product quality

List four common goals of a turnaround

complete the turnaround in the shortest possible time, complete the turnaround doing the check-out of the repair and maintenance jobs, overseeing contactors and standing fire watch

Utility air

compressed air that is used to power equipment and tools

Name two types of atmospheric tanks

cone roof, floating roof and umbrella roof

Explain why corrosive liquid trailers carry smaller volumes than most trailers

corrosive materials are usually denser than hydrocarbons, thus the cargo has a greater weight

Explain why quality is dependent on all operations aspects of a company?

customers may quit buying because the orders were frequently late(shipping department) or the prices and quantities were misquoted, or the quantity was insufficient due to unplanned unit downtime

State when the greatest number of injuries and accidents occur on a process unit

during a unit shutdown or startup

List six hidden defects that lead to equipment failure

dust, sticking, abrasion, looseness, leakage, corrosion, erosion, deformation, scratches, cracks, temperature, vibration and noise

What are the advantages of a standardied format for precedures?

easier to follow the procedure and also easier to find information faster

Explain how you would check the atmosphere in a very large gasoline storage tank in the refinery?

in a large vessel the LEL may be very different at different locations, You must check the multiple locations ( top, middle and bottom). Also the chemicals used in a process will influence the LEL readout or differences in LEL.

Describe two ways that incomplete combustions is detrimental to furnace operations?

incomplete combustions reduces the production of heat and results in accumulation of unburned fuel that becomes a fire or explosion hazard

271.Stokers were developed to__.

increase the efficiency of burning coal B. keep furnace temperatures constant C. allow for development of larger coal-fired boilers D. all of the above*

What is the purpose of a surface condenser?

increase the efficiency, and drops the pressure

Discuss the precautions a technicians should take before sampling a tank

inspect the area around the tank for leaks, check the wind sock, discharge any personal buildup of static electricity, and keep the chain on the sample thief in contact with the metal hatch

The high temperatures and pressure associated with steam can damage _______ and _______

instruments and pump seals

fugitive emissions

intentional or unintentional releases of gases.

Give three reasons for tank gauging

inventory control, custody transfer and oil movement and operations

define chemical test

involves a reaction that changes the chemical composition of the material tested

Composite sample

is a collection of samples from the same sample point over a period of time (usually 24 hours) mixed together in one contanier together in one container to make a composite that represents the material in that vesel or line over that time period

Condenser

is a heat exchanger that is used to condense vapor to a liquid

What is a slurry

is a liquid containing solids or insoluble material

Distillation

is a method for seperating a liquid mixture using the different boiling points of each component.

What is statistical process control?

is a quality tool that uses statistics to continuously monitor process performance with charts and graphs

Define Bad sample

is a sample that does not represent the true nature of the material being required

Define confined space

is an enclosed area which is large enough to enable an employee to enter and perform assigned work, has limited or restricted means for entry or exit, and is not designed for continuous employee occupancy

definition for haze test

is conducted to determine if samples are relatively free of entrained water or substances that cause haze

definition of job aid

is essentially a memory jogger or short list

Explain the purpose of a scale house

is located adjacent to the loading rack scales and will have electronic equipment that tares, the cargo tank, calculates the difference between the loaded and unloaded tank, and prints out a shipping paper or sends the information to the shipping department electronically

Describe duties of the board operator

is responsible for the operation and control of the entire process unit from her console in the control room, Their primary goal is to monitor the board screen and make adjustments as needed

superheated steam

is steam which has been heated to higher temperature than its boiling point

sensible heat

is the amount of heat required to raise or lower the temperature of a substance without causing a change of state

British thermal unit

is the amount of heat required to raise the temperature of 1 pound of water 1 degree Fahrenheit

Differential

is the difference between measurments taken from two seperat points or between two related pressures

Flash zone

is the entry point or feed tray

latent heat

is the heat energy that produces a phase change in a material without causing a temperature change

heat of vaporization

is the heat required to change a liquid to a gas

define heat of fusion

is the heat required to melt a substance

Define endpoint

is the highest temperature records for the distillation test

rectifying (fractionating) section

is the portion of a fractionating tower located between the feed tray and the top of the tower

Definition of economics

is the production, distribution and consumption of goods and services

specific heat

is the quantity of heat required to increase 1 pound of a substance by 1 degree Fahrenheit

Distillation

is the separation of 2 or more MISCIBLE VOLATILE components of a liquid solution by partial vaporization and condensation based on their boiling points.

dew point

is the temperature at which a vapor or gas begins to condense to a liquid

What does the cloud point of a substance determine

is the temperature at which the paraffin (wax) first forms in fuel

What is a pour point?

is the temperature at which the sample will no longer flow

feed tray

is the tray located below the feed line in a distillation tower

What is the purpose of a certificate of analysis?

is to show that is meets the factories standards.

Treated water- Filtered water

is used for these purposes: bolier feed water process water seal water for rotating equipment cooling towers water

List five hazards associated with a unit shutdown

mixing of air and hydrocarbons to form a explosive mixture, water with hot oil, freezing or residual water in pipes or valves, high pressure and temperatures, vacuums, contact with corrosive or toxic materials, poorly trained contract workers, anxiety to meet deadlines

Explain what is meant by an engulfment hazard?

it can bury a worker alive inside a vessel or ditch and fill or plug their respiratory system. it can also strangle, constrict or crush them

Why is steam used as an inert gas for purging vessels and lines?

it does not support combustion and inexpensive

Explain why feedback is essential to good communication

it ensures the message received is understood and yields information about how the receiver of the message is affected by the message

List the three technician position on a process unit

lead technicians, outside technician and board technician

List several consequences of leaking piping and valves

leaks, depending on the nature of the material leaking are a source of fugitive emission and a hazard due to their toxins or flammable nature

critical lifts

lifts that could reslut in death, injury, health impacts, property damage, or project delay if there is an accident.

List the four conditions that affect evaporation of storage contents

liquid temperature, vapor space above the liquid, vapor space ventilation, available liquid surface area

Certficate of analysis

list the required analytical test, the product specifications, and the test values for each test

List the three methods of communication most often used by technicians

logbooks, written reports, radio, telephone, oral

List the two major causes of corrosion in steam and condensate lines

low pH and oxygen

Give three examples of communication filters

lower knowledge level of the receiver, bias about the subject and special points of view, dislike or distrust of the speaker

List eight maintenance duties of process technicians

lubrication, routine maintenance, decoupling of small equipment for maintenance, opening and reinstallation of drain and caps, attending/arresting leaks, v-belt tension adjustments and replacements, arresting flange joint leaks by tightening, observing equipment repair/overhauling, vibration and temperature measurements, conveyor belt off- centering adjustment, fixing coupling and belt guards

What is the purpose of a technician making rounds

making rounds is the one activity that keeps technician aware of the status of their equipment and process conditions in their area of responsibility

List five lubrication systems

manual, gravity, splash, constant level oilers, pressure, oil mist

Lost four things that make up a process or system?

materials, manpower, methods and machines

Explain why technician should not wear their field gear in lunchroom

may be contaminated from handling toxic or hazardous material and in turn may contaminate the lunchroom and food and drink

define specific gravity

measure of the ratio of mass of a given volume.

List the five compounds that make up light ends?

methane, ethane, propane, butane and pentane

Describe the two types of quality for which management is responsible for incorporating into a system?

operations quality and environmental quality

List four categories of bulk solids

pellets, powders, flakes, granules and slurries

Two basic safety concerns that must be addressed during a turnaround are the safety of ___ and _____

personnel and equipment

Dense

phase transport uses high pressure, low velocity air to push slugs materials through the conveying pipe

Dilute

phase transport uses low pressure, high velocity conveying air to completely suspend the solid particles in the conveying pipe

What are outfall samples?

plant water released in ditches and streams

What information is contained in the daily operating instructions?

product scheduling, daily operating objectives or targets, special operating nstructions, maintenance schedules

The function of the lock out/ tag out permit is to

protect employees form hazards associated with the accidental release of uncontrolled energy by isolating a piece of equipment from its energy source

What information is contained in specification sheets?

provide informationabout the products produced by the unit

List four safety factors technicians must consider when loading and unloading cargo tanks

pulling a vacuum, static electricity, containing spills, housekeeping and emergency shutdown systems

246.The __ pump draws fuel oil from the fuel oil tank

r B. fuel oil

Expansion valve

reduces the pressure of a liquid refrigerant, causing it to cool

List five major reasons for the proper lubrication of moving equipment

reducing wear, cooling moving pars, dampening shock, preventing corrosion, flushing out contaminants

List the four basic techniques for unplugging and cleaning piping and equipment

removing the plug by using pressure, mechanical methods, apply external heat, cleaning with solvent, acid or caustic solution

Which of the following statements best applies to potable water?

safe to drink

List the five reasons for a unit shutdown

schedule turnaround, unit inspections, major equipment problems, emergency situations, business reasons

Explain how tote sacks are designed to prevent accidents caused by static electricity

some sacks have metallic wire woven into the fabric to provide a ground wire that can carry away the static charge

Describe how a technician could check for leaking relief valve?

sound (chatters and whistles), changes in the appearance of a flare and temperature difference in a relief line

Which of the following is NOT a potential hazard if someone attempts to open a motor controlled valve manually?

sound of alarm

List four ways to detect gas leaks?

sound, streamers, soap solutions, scents and portable leak detectors

What sampling technique would you use to determine if a storage tank is well mixed?

spate bottles are lowered to collect samples from top, middle and bottom of the liquid level in the tank

What information can you find in the operating procedures manual?

startup, shutdown, emergency procedures, plus normal operating procedures, safety information

List three methods of purging equipment

steam purging, water purging and purging with inert gas

Name the two drivers for cooling water pumps

steam turbines and electricity

Outage gauge measure

the amount by which a vessel falls short of being full

Discuss how changes in furnace fuel gas affect furnace efficiency?

the amount of heat generated is determined by the fuel being burned. changing the fuel mixture requires adjusting the fuel floe and combustion air

Custody transfer

the measurement of product transfer between the production site and the external customer

lockout device

the placement of a lockout device on an energy source, in accordance with an established procedure, that ensure the energy is isolated and the equipment cannot be operated until the lockout device is removed.

Discuss why the quality of repair is important to a turnaround

the quality of the repair work has an impact on time and cost. Quality guidelines should be prepared and issued to establish the minimum acceptable level desired. Operating personnel should have access to these minimum levels. Poor quality can result in accidents, rework and equipment failure

How does a gauge hatch act as a pressure relief device

the tank literally burps through the gauge hatch when the inside of the tank overpressures

define initial boiling point

the temperature at which the first drop of condensate is collected

List three problems caused by excessive piping vibration

threaded connections can loosen, flanges can start leaking, pipes can be knocked off their supports, and in extreme cases, pipe fatigue failure can occur. Excessive vibration can cause equipment and piping failure

Why are pre-transfer inspections made in cargo vehicles

to check the cargo vessels for leaks, cracks and obvious damage, proper safety equipment, heel and placarding

Explain the function of the permit system?

to force personnel involved in a task, often hazardous to take the time to review all the steps, PPE, hazards, and equipment required to perform the task safely. The permit responsibilities on the issuer of the permit and the recipient of the permit

List the three steps for the transferring of bulk liquids

weighing and spotting, making connections and transferring the liquid, disconnecting and releasing

Screw conveyors are commonly used for what tasks

when materials must be transferred at very low speeds. they are also used for injecting additives, extracting samples, and as mixers and stirrers to mix and blend dry or fluid ingredients

Explain how a tank foam over occurs?

when water vaporizes below the surface of hot asphalt or heavy oil and expands in volume

Briefly describe the duties of the outside technician

will be assigned to one of the outside area of an operating unit, docks, or tank farms. They will be responsible for the ongoing operation of that area, the maintenance of the area equipment, and the security and safety of the area. They will spend a significant amount of time making area rounds to asses the status of their area

Why do we bring the steam rate up slowly on start up

you don't want thermal shock

4. List two hazards of water in a process unit.

• A big danger from water that accidentally enters a refining unit is that it can flash to steam and create pressures inside a vessel that will cause internal damage or a rupture. • When water is being used to purge air from process equipment by flooding. Water can be a hazard due to its weight. Water is 25% heavier than hydrocarbons. The water flooded vessels and structures must have sufficient strength to hold the weight of water and their foundations must be able to safely withstand the added weight.

Given all the ways operators can impact the economics of a unit, how would you choose where to place you efforts to obtain maximum economic benefit? Operators can impact the units economics by:

• Being conscientious • Understand their roles • Know how their equipment works • Make good routine checks of all their vessels, lines, and equipment. • Know how to handle emergencies and problems.

List five important process unit documents.

• Daily operating instructions (DOI): Written by the unit superintendent or operating engineer and are located in the control room. The instructions include information that technicians need to know about product scheduling, daily operating objectives or targets, special operating instructions, maintenance schedules, etc. • Operator Logbook: Is located in the control room and maintained by process technicians. Most logbooks are the written passed-down information for an area of responsibility and include all information pertinent to the safe and efficient operation of that area. Safety hazards, equipment problems, operational problems, and operational adjustments made during the shift are entered into the operator logbook. • Product specification sheets: Provide information about the products produced by the unit. If the unit produces different grades of material, or completely different products, each grade or product will have its specification sheet. • Certificate of analysis: for a unit product. Example, if the unit loads a truck with styrene monomer, the laboratory analysis of the truck sample is compared to the specification sheet and then recorded on the certificate of analysis. This is a way to prevent off-specification product from being shipped. • Material safety data sheets: provide information concerning the hazards of the chemicals present in the unit.

9. Identify four physical tests and explain why they are important to technicians?

• Distillation Test: Are used to indicate the volatility of a product. • Vapor Pressure Test: Vapor pressure is important when determining safety procedures and the handling and storage of chemicals. • Flash Point Test: A very low flash point will cause fuel to be a fire hazard, subject to flashing, and possible continued ignition an explosion. • pH Test: The pH of water discharged into the environment is carefully monitored for environmental compliance.

1. What is the definition of economics? Why are economics important to a technician?

• Economics is the production, distribution, and consumption of goods and services. • Because the process technicians standard of living, will be determined by the productivity of the of his process unit. And competition in the processing industry is global.

3. What are some of the economic considerations a technician should consider for boilers? To minimize boiler expenses, operators can do several things.

• Ensure boilers are tuned. • Eliminate scale • Minimize corrosion • Maximize condensate return

2. What are some of the costs that impact the economics of a process unit?

• Having to repair equipment. • Fuel • Steam • Compressed air • Electricity and water • Product by running off specification • Raw materials

List three types of permits required by OSHA 29CFR 1910.

• Hot work permit • Confined Space • Cold work • Radiation • Electrical • Lockout/Tagout

4. What are some economic considerations for exchangers?

• If possible, allocate the more fouling fluid to the tube side • Design for a fouling fluid velocity of 5 ft./sec on the tube side and 3 ft./sec on the shell side • Try to keep the fluid velocity constant • Allow for easy access for cleaning • In water service, ensure the tube wall temperature is not too high to create salt deposits or render treatment chemicals ineffective • Do not throttle water flows in winter time

Explain why feedback is essential to good communication.

• It verifies the other person has understood your message. • It allows you to react to what the listener has said and done, yielding further information to the speaker.

List the three technician positions on a process unit.

• Lead technician • Outside technician • Inside technician

Describe three hazards of light ends.

• Light ends are hazardous because they will evaporate rapidly at room temperature and pressure. • To keep propane a liquid at 100 degrees F, it must be kept at a pressure of at least 189 psi; normal butane, 52 psi; and isopentane, 21 psi. If these pressures are not maintained, the liquid will quickly vaporize. A small amount of liquid leaking from equipment will vaporize into a large vapor cloud that can spread quickly and cause a large explosion and fire.

List three maintenance duties of the outside technician.

• Lubricating equipment • Tightening valve packing nuts for packing leaks. • Changing and cleaning numerous in-line filters • Replacing gaskets.

List five communication responsibilities of technicians.

• Maintain logbooks • Order replacement materials and supplies. • Write clear instructions. • Complete and route forms and bills of laden. • Communicate with maintenance, lab, or technical services. • Fill out checklists. • Receive shift change information when making relief.

List five applications of written communications used by technicians.

• Memos and notes • Charts and graphs • Meeting minutes • Reports • Training manuals • Written instructions (daily operating instructions and night orders) • E-mail

1. What are some of the risks we can encounter when taking samples? Samples might contain hazardous compounds that fall into one of the following categories:

• Mutagen • Teratogen • Neurotoxic • Flammable • Toxic • Carcinogenic • Corrosive • Allergen

List three methods of communication constantly used by process technicians.

• Oral • Written • Nonverbal

Discuss how nonverbal communication aids in communicating.

• Raised eyebrows indicate interest. • Making eye contact and leaning toward the speaker show readiness to assist the speaker. • A hand around the throat and / or around the body indicate the listener needs reassurance. • Closed eyes and nose pinching reveal inner confusion and conflict.

Coating of coke reduces the rate of flow through the tubes and reduces the efficiency of the furnace.

• Reduces the transfer heat through the tube wall. • Increases the amount of fuel needed to heat the product to the correct final temperature. • Reduces the efficiency of the furnace.

3. How do sample tanks have a stratified layer? What can be done operationally prior to taking the sample?

• The contents of many storage tanks stratify if the tank isn't constantly active. It is not uncommon to have three different zones in a storage tank with each zone having a different chemical composition. Lighter material will migrate to the top zone, heavier materials to the bottom, and the rest in the middle zone. To get a representative sample the taken will have to be mixed or samples collected form each zone and mixed together.

6. Name 5 precautions we must take to insure accurate sampling.

• The sample may be taken form a dead spot in a vessel where stagnant material not representative of the mainstream has collected. Sample points should be relocated if they ae located near dead spots. • Long sample lines (8 to 10 feet long) trap a lot of sample. Are referred to as dead legs. The line must be purged long enough to drain all the old material in the line, so the composition as the last sample taken form this point. • Samples may be collected in the wrong container and invalidate the sample. It is critical to use the correct sample container for each sample. • A volatile material may be sampled while too hot and its lighter components may vaporize, fractionating the sample and leaving only the higher boiling components behind. • Samples taken during a period of unit upset, or just before or after the upset, will not be representative. During these times operating conditions and product and process compositions are changing. Except for certain check samples to be used for guidance, all other samples may be useless.

7. Identify when we use gas detectors and what are they used for. What can go wrong when taking samples?

• To assure compliance to environmental regulations. • Detecting fugitive emissions. • Protect employee and contractor safety and health. Precautions must be taken when using detector tubes because moisture or particulates affect their performance.

5. Provide several examples of why we collect samples?

• To determine the chemical properties of various process streams. • To predict the properties of the finished products. • To know the chemical composition of the finished product and the process streams.

5. What are some of the economic considerations for process heaters? Flame Impingement: can cause expensive results.

• Tube oxidation (destruction) • Product breakdown • Lowered product flow rates • Increased fuel requirements • Reduced production


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