BOILER

OPERATOR'S
EXAM
PREPARATION GUIDE
~ Easy to understand
~ Reviews all exam topics
~ 457 multiple-choice, essay,
and number problems with
detailed solutions
~ Covers the whole process
from heat theory to practical
operations

Theodore B. Sauselein
www.facebook.com/BoilerandMechanicalPower

Lib...,. of~ Calaloclac lD Publloatloe Data

S.U..Un,'l"beodonB.
The boiler opera c.«'I e:u.Jn prepantion eulde /'l'beocklre 8 . S.uttleln
p. em.
ISIIN 0.07~7-7
L St.am·bollan-Eu.miDatkaa., queatioD&. ete. I. '1'\~-.
TJ289.8!3 1996
621.1'83'016-daO 95-347W
CIP

McGraw-HiU gz
Ao;-.</llo-~

Copyriaht ~ 1997 by The Mc0raw Hill Compukllt, Jn.t. All riabtt

4

l"eM':l"V'ed. Printed in. the UNt.ed St.ata or ~ca. Eaoept u pennlued

u.oder the United S~\c$ Coppightktof 1976. AO p4rtolthit publi(ation
m ay be reprocfua:d or dl.t.ributed i.o any Corm or by arry me&n~, or doted
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the publiaher.

67890 KGPil<GP 03

ISBN 0·07·05796$-7

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Priftltdaod~'\<•pon.

MtCra•·ffiU booka are available at ~al qu.enllty dh<:auntt to I.I.SO ••

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Ur cocrrechlhch chulzl M 101 "

 Contents

lntroducllon; T.aklng 1M Toat I

Chaplet One Heat

Chaplet Two I!OIIeta 15

Chaplet Three Boiler T~m .,

Chaplet Four COmbuaUon eo
Chapter Five Fuel-Burning Equip ment 109

ChapJer Six Fu e~Savlng Equipment 133

Chapter Seven Steam Traps and Pipes 1<1

Chapktr ElghC Water Treatment 151

Chapter Nino Turbines 165

Chapter Ten Pumpa ond Motors 17D

Chapter Eleven BeaMga 213

Chapter 1Welve s.mple Multiple Choice Questions 221

Chaptot Thirteen EON)' Questlona 25i

Chapter Fou'*n Anowera to Multiple Choloo Qu..Uona 271

Ill
Cl\opter F - £Nay Ana_.. 276

Appandla - • Slum Tables 315

Gloeaaty 328

Ur cocrrechlhch chulzl M 101 "

Taking the Test

Here ~ a few tips when taking your licensing examination:

Select what appears to be lbt most torrect answer.

While examiners swear that there is only one obvious correct answer to a
q-uestion. you may find that either none or more than one of the choices is
obviously correct. Instead of trying to figure out which is the correct answer,
eliminate those that arc obviously wrong and then narrow it down to the most
correct answer.

Don't cct bung u p on one question.

Go through the test and answer the questions you de finitely know. The.n go back
and work on the ones you skipped. The last thing you want to do is expend all
your nervous energy on a hard question at the beginning of the test. Don•t be
surprised i.f, after going through the test several times, there are still a few
questions that make no sense. If that's the case, just give them your best guess.

Learn defmilions.
A lot of multiple choice questions are based on definitions. Take the following
example:

Convection means
a) the movement of liquids or gases created by a temperature difference.
b) transfer of heat by direct molecular contact.
c) the weight of a substance as compared to unit.
d) a form of heat transfer by waves.

The correct answer is a. but change the question to radiation m~ans or conduc·
tion means, and the correct answer is then d and b. respectively.

l.ntrodvdtoo i

ch11 hl '"'
MATH PRoBLEMS AND UNITS
Wilen working a math problem, always assign unios to the numbers in the
problem. Wilen the equation is set up, the units should work out to the units
you expect. If not. then the equation is not set up properly. Consider the follow-
ing problem:

The water surface in a ftte tank is 135 feet above the suction of a ftte pump.
What is the psi at the suetion of the fire pump?

You remember the conversion is 2.31, but the question seems to be, do you
multiply or divide 2.31 by 135 feeL But the question is really 2.31 what?! Every
number that is wtincn dnwn should have units attached to it. Wilen these num-
bers. especially coo.versions, have units, then the math becomes much easier.
The correct measurement is actually 2.31 feet/psi. Let's say your first guess is
to multiply 135 feet by 2.31 feet/psi (at this point don' t worry about the num-
ben, just concenlnlte on the units):

Obviously £ect2 per psi is not the answer you were looldng for. Now divide 135
feet by 2.31 feet/psi:

Itot
- - •p$i
toeVpsi

This is more like il The unit you were expecting was psi. Now that the problem
is act up properly, just add numbers to the WliiS and let the calculator dn the
number crunching:

13Sh
231 h/psl = sa.•• "'1
Some examiners insist that you show all steps to the solution. This method
automatically makes you show aU your work- Even if you don't come up with
what the examiner thinks is the cor=t result. if your work is laid out in an
easily followed fashion partial credit might be given.

Now after all this ta1Jc about units, there are some numbers that are dimension-
less. It's not that these numbers sto.ned out lacking units; it's that all tbe Wlits
canceled themselves out. Percentages, efficiencies, and ratios like ~ (pi) are
examples.

ii The Soller Operotof"s hom PN:porotion Guide

Ur cocrrechlhch chulzl M 101 "

From elemenlal}' school you learned that the equation for the area of a cir<le is
m-1.This same equation can also be written u 0.78S4d1• Use whichever one
you feel most comfortable with.

With that in mind. let's ftnd the area of a 6 foot diameter circle. The answer
mus1 be in square inches.

0.7854 • d' = 0.7854 •16 hi' • 144 ;n11lfl • 4,071.51 ;,t

The S3Jile problem can also be worked out as follows:

6 ft d~meter clrde • 3 ft tOdius
3ft x 12 in./h • 36 inches
"" - 3.14 • {36 ln.J' - 4,069.44 In'

Notice the answers are close but not exact. The problem here is how many
decimals 10 use with n. Usually two decimal places is plenty. The important
thing is to show all your work.

Anothet advantage of using units is that you are forced 10 do all the conver-
sions. In the previous example, diameter was given in feet, but the answer had
to be in inches. You can bel your bonom dollar that if this were a multiple
choice question, it would include the answer that did not have feel conveJ1ed 10
inches. You would work the problem without convertina. then be relieved that
the incorrect answer you came up with wu included in the choices.

Malee sure your calculator can do square roots. There are a few problems where
this feature comes in handy.

lnkOdudiof't iii

Ur cocrrechthch chulzt M 101 "

CoNVERSIONs
Now foe conversions. Since mou tests are closed boolc. these will have to be
leamed or memoriud:

1 In, Hg = 0... 91 psi

1pti - 2.31 ,••. _
11<>o._ = 0.~33 psi
1 hp • 0.746 kW
= 33.000 h.lb/m;n
• 2,545 Btuh
I kW • 1.34 hp
• 3,413 Btuh
1 ool • 231 in1
- 8.33 1b -
wbic foot of wo!er • 7.48 golk;wu
• 1,728 in3
• 7.•8 gollom
1 bollet 1-.oN:epower e evopomtion of 34.5 lb_.../ht from ond ot 21 'rF
• 33,475 Btuh
'f = rc • 9t5J + 32
-c - 5/9('f • 32)

One British tbennal unit (Btu) is required to raise tbe ~mpcrature of ooe pound
of wa~ l'F and is equal to 778 ft·lb or work

Atmospheric pruoure of 14.7 psi• will sustain a column of wmr 34 feet high
and a column or mercwy <Hal 29.92 inches high.

EQUATIONS
The following are a few of tbe equations you will ha\·e to memorize:

OteO of 0 cltde - 0.78S.d'

c.lrQimference of o clrde • ltd
to<que a 15,252 X hp)/'P"'
Btv/tb of oil • 17,780 + 154 x API g«>vi~)
heoting volue of cool • 14,000 Btu/lb

...
heotlng ¥Clue of fvol oil • 19,000 Btu/lb
Btu!lb,. = 17,687 + (57.7. AJ>I g..,...;!y)
pd
longitudit\01 streu

c.ircvmferentiol mess = ~
21

;., The Boilet Operok)t's D.om Preporofion Guide

Ur cocrrechllich chulzl M 101 "

Boilers
The equation for JruiXimum allowable working pressW'C (MAWP) is:

TSxt•E
p- """'R7FS

w~:
P c maximum allowable working pressure in psi Inside drum or shell
TS = ~ensile sttength of plate (psi • use SS,OOO psi for steel)
' a thickne$a or plate (inches)
R = inside radius or drum or shell (Inches)
FS a factor of aafety (ultimale slrength divided by allowable working
stress or bursting pressW'C divided by snfe working pressure. It can
vary between four and seven depending on age, type or CODSitUC·
lion, and conditioo. Use five for most calculations.)
= efficiency of lhe joint (for welded joints, use I~)

For bursting pressure, SCI lhe factor of aafety 10 one.

The equation for boiler horsepower is as follows:

lb__./h( x Fodor of ~YC~porolion

34.5 lb..JBoia.r hotMpow.r

Where the factor or evaporation is:

Btu-~ • (Feedwo•er tempetotwe · 32'f)
970.3 Bou/lb

The equation for boiler efficiency is u follows:

lb,_.l1b,.. , (Bru!lb_ • (Feedwooe• ,...,._,,. • 32"f))

Blv/lb,.,

Pumps
To calculate horsepower, use the following equation:

lblgol • Heod (foeo)

Ql'f'\ ' 8 .33
33,000 ft·lblmln x Efficiency

tntrodudion v

Ur coc•rechlloch chulzl M lor "

Or the following equation may be wed to calculate horsepower:
gpm • H.ad {feer)
3,960 X Eff;c;;ency

To calcula1<: the gpm of a reciprocating pump. usc tho foUowing equation:

lANE
gpm -FI
whore:
l = length of stroke in inches
A = area of piston
N = number of strokes per minute
E • efficiency
231 = number of cubic inches per gallon

Nott: A strok-e is a piston moving once o~er its path. For a duplex pump. a
stroke is botlt pistons moving once over tMir path.

Turbines
For condenser cooling water, use the following equation:

where:
Q • weight of water to condense I lb of s1eam
H =best content of exhaust steam
10 r temperature of condensate
T1 = tcmpcranm: of cooling water cn1<:ring condenser
T2 :: temperature of cooling water leaving condenser

The equation for torque is:

hp X S,2S2
•pm

where:
5,252 = constant that converu radians to rpm

Ur cocrrechlltch chulzl M lot "

For pipe expru>Sion. use the following equation:

rr' . T2l )( l If Coe fficient of expansion II 12 in / h

where:
coefficient of expansion for steel = 0.0000065 ioJio.·'F

To calculate pipe size. use the following equation:

where:
A = area in squan: inches
Q = quantity of steam in cubic fC<:t per minute
V =velocity in feet per second
144 • number of square inches per square foot

Become familiar with different steam pressures and their corresponding tempera-
tures ond heat content.

in. Hg in. Hg
vacuum ob1olule psia 'f eu 11/lb Btu!lb
29' 1' 0.491 79 652 1.1 04
28' 2' 0.952 100 340.4 1.105
27' 3' 1.473 11 5 231 1.111

psi psia 'f <u 11/lb Blu/lb

15 30 250 13.7 1.164
100 115 338 3.9 1,189
150 165 366 2.75 1,196
200 215 388 2.13 1,199
250 265 406 1.8 1.202
285 300 417 1.5 1.203
585 600 486 0.77 1.203

Ur cocrrechthch chulzl M lout

Heat

While lhe concept of thermodynamics may sum a lillie daunting, it is neces-

sary to know a little about i~ as it lays lhe foundation for everything that
follows. What is more important is that it also helps with some le$t questions.
Understanding ~rms such as senslblt htar and kuem htar and knowing what
happens when water changes to steam will help you understand what happens
in boilers and steam traps.

HEAT TRANSFER
Let's begin by examining the proc:css of changing water into steam. The beat
energy from fuel Is delivered to lhe water by lhrce methods of transfer. radia-
tion. conduction, and convection:
lbdiadoo does not require a transmission medium; it travels like light
waves lhrough a vacuum and through air. The most common example of
radiation is the heat we feel from the sun.

Coocludlon is the transfer of heat from a warm molecule to a cooler one.

Some ma~rials conduct heat bener than others; for example, gases and
vapors arc poor conductors, liquids arc beuer. and metals arc best. Mllteri·
als that are poor heat conductors, like asbestos and calcium silicate, are
called inJulaton. Heat travels through insulators but at a slower rate.

Convection heat transfer W:es place by movement of the heated material

itself. In a heated room. warm air rises and lhe cold air falls. In a boiler,
the hot w&ter riSc:s and lhe cold w&ter falls to lhe bottom.

Now it is possible to see bow the lhrce forms of beat transfer work in a boiler.
The tubes in the furnace section of lhe boiler receive !heir heat by radiation
from lhe visible flatne. In fact. about half of the steam in an industrial boiler
and all lhe steam in a utility boiler is generated by the furnace tubes. The part

Heat 1

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