BOILER OPERATOR TEST :

1) What is the Boiler capacity , Pressure & temperature ?

40 TPH, 28 KSC, 380° C
2) What is the Boiler Drum safety( LHS & RHS )valve lifting pressure?
3) Draw the boiler water & steam flow chart ?
4) Draw the boiler fuel ( coal ) flow chart?
Coal yard ---- Crusher --- screen ---- Conveyor --- Bunker --- Coal feeder -
--- Vertical chute --- Mixing nozzle --- PA line ---- Cross --- Coal nozzle –
furnace .
5) Draw the boiler Air & flue gas flow chart?
6) What is the function of Feed pump & feed control valve ?
Feed pump is using to fill the water from De aerator storage tank to steam
drum with high pressure, feed control valve is using to maintain the drum
level in boiler.
7) What is the use of IBD,CBD valve.& what is mean by IBD,CBD?
IBD valve is using to give blow down ( drain the water from mud drum )
for controlling the silica in boiler water.
CBD valve is using to drain the water from steam drum, continiousely, for
maintaining the TDS,PO4 & conductivity in blow down water.
8) What is the use of Economizer?
Economiser is using to pre heat the boiler feed water, from boiler out let
flue gas.
9) What is the use of Air pre heater?
Air heater is using to pre heat the compustion air ( FD fan outlet air ) from
ECO. Out let flue gas.
10) What is mean by ESP ?
Electro Static priciptator. ( By CARONA EFFECT )
 11) What is the use of ESP?
ESP is using to remove the fine ash particles from flue gas, by carona
effect. For this we are using the step up transformer , for making 380 volt
to 120 Kilo Volt.
12) What is mean by cold start up of boiler & Hot start up of boiler . explain?
Cold start up – after cooling down the boiler up to atm. Temperature&
pressure, again we start the boiler by using dry char coal ( 150 kgs & diesel
mixed 80 kgs ).
Hot start up – If any reason boiler or turbine trips or slump the boiler with
bed temp. above 600 deg. C & AGAIN WE START THE BOILER WITH THE
SAME BED TEMP. & PRESSURE .
13) What are the valves should be kept open , before start the boiler?
Drum air vent, MSL air vent, ECO inlet, All transmitter Iso. Valves,MSL
drain valves,BFP suction & Discharge , De aerator out let valve.
14) When you close the Air vents in drum & Main steam line?
When the Steam pressure reaches 3.0 KSC , that time we should close the
vent vlave.
15) How many valves in Main steam line?
Air vent, Auxiliary vent, Pr. Gauge ISO. Valve , Pr. Tr. Iso. Valve , Remote
pr. Gauge iso. Valve, Start up vent valve ( iso. & MOV ), Stop valve &
Bypass valve& Safety valve.
16) When you close the Main steam line drain ?
When the Steam temp. reaches above 300 deg. C.
17) What is the procedure of steam line charging?
18) How many local level gauges in Steam drum?
Two nos.
19) How many safety provided valves in this boiler & where?
In steam drum – 2 nos & MSL – 1 no.
20) How to control the Main steam line steam temperature?
 By opening the spray control valve , spray Through DSH in between the
CSH O/L & RSH I/L header.
21) What is the drum level low & high alarm?
Low alarm – 35 %, High alarm – 75 %.
22) What is the tripping level in drum ( very low & very high )?
Very low trip – 22 % & Very high trip – 88 %.
23) What is the interlock of feed pump & when the pump will trip?
De aerator level low ( feed back from low level switch ), Suction strainer
pressure high at 500 mmwc. & Motor over load (196 amps.)
24) What is the sequence of fan starting ?
Drum level normal , ID fan, PA fan , PA suction damper, PA compt. Damper
FD compt. Damper & FD fan .
25) What are the chances of ID fan tripping?
Drum level very low or very high, Motor load high ( above 147 amps ).
26) What are the chances of PA fan tripping?
When ID trip, Motor over load,( 55 amps )
27) What are the chances of FD fan tripping?
When Dr. lvl very low, very high, ID fan trip, PA fan trip, & when furnace
pressure goes to above + 15 mm & motor over load ( 324 amps )
28) What are the chances of Coal feeders tripping?
When the PA compt. Close, FD compt. Damper close, FD fan trip , Feeder
motor over load.( in auto – bed temp. very high 975 deg. C & low temp.
600 deg. C )
29) What is the De aerator operating pressure?
0. 23 KSC ( G ).
30) What is the safety in de aerator, when the pressure goes above the
design pressure ?
 Loop seal assembly provided in de aerator storage tank, when the
pressuregoes above the 0.35 KSC , automatically the excess steam &
pressure will drain outside through Loop seal assembly.
31) How to maintain the De aerator level?
By opening the Level control valve & by controlling the Condensate pump
outlet valve.
32) What is the full load current of ID,FD,PA & BFP 1,2?
ID fan – 147 amps, PA fan – 55 amps , FD fan – 324 amps & BFP 1, 2 –
196Amps.
33) Write the procedure of cold start up & Hot start up?
34) What are the main activity to be done , at that time of Turbine trip &
boiler trip?
35) What is the chemical using in LP dosing & why?
36) What is the chemical using in HP dosing & why?
37) What are the air flow setting for 1,2,3 & 4 compartment?
For 1 compt- 15 – 17.5 mm, 2 compt.- 35 – 40 mm, 3 compt. – 75 – 80 mm
For 4 compt. – 105 mm – 115 mm.
38) What is the location of CBD,IBD valve & from where it is coming?
CBD from Steam drum, IBD from Mud drum bottom .
39) How many coal feeders per compartment?
Two feeders / compt.
40) How many PA lines per compartment?
4 lines / compt.
41) Draw the PA line from starting to end?
PA header – PA compt. Damper – branch header --- 4 lines --- line damper --
- mixing nozzle --- PA Pipe with flange & pocking hole ---- Cross --- vertical
drain with Gate arrangement ---- Vertical line to coal nozzle – coal nozzle.
42) How many coal nozzles per compartment ?
4 nos / compt.
43) When you check the PA line mixing nozzle & what is the reason for
checking?
Before starting the boiler & at the time of fluidizing checking ( before bed
hight checking ) & Before take the compt. In service with coal feeders.
44) What is the Bed material size for this CVL boiler?
0.8 mm to 2.36 mm .
45) What is the Coal size ?
Below 6mm ( - 6mm ).
46) What is the char coal size & how much kgs using for start up?
15 to 25 mm & 150 Kgs Dry char coal + 80 kgs diesel mix.
47) What is ID fan, FD fan& PA fan?
IDF- Induced Draught Fan
PAF- Primary Air Fan.
FDF- Forced Draught Fan.
48) What is the indication of feed pump suction strainer jam/ chocke?
We can see the Suction DP Gauge Reading & Suction pressure will come
down.
49) How to change over the Boiler feed pump.& when?
50) What is mean by LP Dosing & HP Dosing?
LPD – Low Pressure Dosing ( connected to BFP suction )
HPD – High Pressure Dosing ( connected to Steam drum )
51) What is the purpose of O2 analyzer & where it is ?
On line analyzing the O2 % in flue gas at ECO outlet duct.
52) When the ESP can start / Charge?
After reaching the flue gas temperature at 110 deg. C.
53) What is the Sample cooler & what is the use of sample cooler ?
Sample cooler is a device to make the condensate of Heat water & sat.
steam & super heated steam by cooling water, for taking the sample of
 feed water , blow down water , sat. steam & super heated steam sample
for analyzing .
54) How many sample cooler in boiler?
4 nos.
55) How many Bed material drain line per compartment?.
2 nos / compt.
56) What is the use of Bed material drain?.
To drain the bed ash from bed zone & cleaning the bed.
57) How many Ash feeders provided in this boiler & where?.
Bank zone – 2 nos , ECO. – 2 nos , APH – 2 nos & ESP – 2 nos.
58) What is the limit of PH, silica , TDS, Conductivity in feed water?.
59) What is the limit of PH, silica , TDS, Conductivity in Boiler water
60) What is the limit of PH, silica , TDS, Conductivity in Steam?.
61) How to control the silica in Boiler water ?.
By giving the IBD drain in shift.
62) How to clean the strainer in feed pump?
63) What is the use of start up vent.?
To make the circulation through super heater coils at that time of boiler
start up for getting the super heated steam & if any emergency we can
reduce the pressure by opening of vent valve.
64) What is the use of temp. control valve.?
To control the steam temp.
65) What is the use of Feed control valve.?
To maintain the steam drum level.
66) Why the Air vent valves kept open before start the boiler.?
To release the air in boiler empty places ( coils & drum )
67) Heating surface of the 40 tph boiler --------------.
68) What is the RO plant capacity?
16 CU. M
 69) How much O2 % should be maintained for getting better efficiency ?
70 ) What are the actions should be taken at that time of PA Line choke ?
71) What are the actions should be taken at that time of Coal jam in bunker ?
72) What are the actions should be taken at that time of coal empty in any one
Bunker ?
73) What are the actions should be taken at that time of Ash level high in ESP
Hopper ?
74) What are the actions should be taken at that time of ,the Air flow showing
wrong indication ?
75) What are the actions should be taken at that time of operating computer
Hang ?
76 ) What are the actions should be taken at that time of any tube failure ?
77) What are the actions should be taken at that time of Feed pump discharge
orifice flange gasket failure ?
78 ) What are the actions should be taken at that time of Feed piping flow orifice
Flange gas ket failure ?
79) What are the actions should be taken at that time of running feed pump trip ?
80 ) How to clean the PA line ? ( When jam )
81 ) List out the daily checking in the boiler , by operator in every shift ?