Operations set 1
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
