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Boiler Operator Exam Preparation Guide-Theodore
Boiler Operator Exam Preparation Guide-Theodore
Boiler Operator Exam Preparation Guide-Theodore
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
McGraw-HiU gz
Ao;-.</llo-~
67890 KGPil<GP 03
ISBN 0·07·05796$-7
Priftltdaod~'\<•pon.
Ill
Cl\opter F - £Nay Ana_.. 276
Gloeaaty 328
Learn defmilions.
A lot of multiple choice questions are based on definitions. Take the following
example:
Convection means
a) the movement of liquids or gases created by a temperature difference.
b) transfer of heat by direct molecular contact.
c) the weight of a substance as compared to unit.
d) a form of heat transfer by waves.
The correct answer is a. but change the question to radiation m~ans or conduc·
tion means, and the correct answer is then d and b. respectively.
l.ntrodvdtoo i
ch11 hl '"'
MATH PRoBLEMS AND UNITS
Wilen working a math problem, always assign unios to the numbers in the
problem. Wilen the equation is set up, the units should work out to the units
you expect. If not. then the equation is not set up properly. Consider the follow-
ing problem:
The water surface in a ftte tank is 135 feet above the suction of a ftte pump.
What is the psi at the suetion of the fire pump?
You remember the conversion is 2.31, but the question seems to be, do you
multiply or divide 2.31 by 135 feeL But the question is really 2.31 what?! Every
number that is wtincn dnwn should have units attached to it. Wilen these num-
bers. especially coo.versions, have units, then the math becomes much easier.
The correct measurement is actually 2.31 feet/psi. Let's say your first guess is
to multiply 135 feet by 2.31 feet/psi (at this point don' t worry about the num-
ben, just concenlnlte on the units):
Obviously £ect2 per psi is not the answer you were looldng for. Now divide 135
feet by 2.31 feet/psi:
Itot
- - •p$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.
With that in mind. let's ftnd the area of a 6 foot diameter circle. The answer
mus1 be in square inches.
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
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:
...
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
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~)
Pumps
To calculate horsepower, use the following equation:
tntrodudion v
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
where:
5,252 = constant that converu radians to rpm
where:
coefficient of expansion for steel = 0.0000065 ioJio.·'F
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
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.
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