Question for knowledge test of the operators

A.

TRUE OR FALSE
PLEASE ANSWER THE FOLLOWING QUESTIONS BY CIRCLING "T" FOR
TRUE AND "F" FOR FALSE

1.

CRUDE heaters are force draft furnaces

T
F

2.

CRUDE furnaces are also designed for natural draft

T
F

3.

CRUDE furnace can run without ID fan

T
F

4.

CRUDE furnace have four main flame detectors in each pass

T
F

5.

CRUDE furnace have individual pilot gas flame detectors

T
F

6.

In normal furnace operation, furnace will trip if all pilot gas flame detector fails
T
F

7.

Pilot gas pressure low will trip the furnace.

T
F

8.

Velocity steam may is injected in four locations

T
F

9.

Emergency steam to coil will open when heater trips.

T
F

10.

Emergency trip of heater from control room cut off the pass flows, furnace firing
and open emergency steam to furnace coil.
T
F

11.

Furnace will trip if any of the two pass flow measurement for ESD become zero.
T
F

12.

Leak test is must before re-lighting the burners.

T
F

13.

Furnace damper operation is either full open or full close.

T
F

14.

There are 14 nos of soot blowers in each furnace.

T
F

15.

Soot blowers can be operated from control room.

T
F

16.

FO/FG valves of individual burner should be fully open.

T
F

17.

Less atomizing steam will make the FO burner flame short.

T
F

18.

High skin temperature of the furnace tube indicate scale formation on the tube.
T
F

21.

Pigging operation cannot be done on-line.

T
F

22.

Every fired heater is provided with two explosion doors .

T
F

23.

Flue gas temperature below 177OC can cause corrosion..

T
F

25.

VR is measured by Wedge meter.

T
F

26.

Flue gas leaves the radiant setion at 7250C.

T
F

27.

CRUDE heatres are equipped with combination type burners.

T
F

28.

CRUDE heaters have Pre-mix type burners

T
F

29.

Velocity steam to the radiation inlet is only DCS controlled

T
F

30.

At the start up of the heater snuffing steam is used to creat draft inside the
furnace.
T
F
MP steam is used as snffing steam in the Heaters .
T
F

31.

B.

MULTIPLE CHOICE
PLEASE ANSWER THE FOLLOWING QUESTIONS BY CIRCLING THE
BEST ANSWER

Tick the correct answer

1
BMS stands for
A
Burner material system
B
Burner management system
C
Burner Main supply
D
Burning material smoke
2

Most efficient furnace is

A
Natural draft furnace
B
Force draft furnace
C
Balance draft furnace
D
Induced draft furnace

Most heat transfer zone in the furnace is

A
B
C
D

Convection zone
Radiation zone
Stack
Burner floor

Heater trip means

A
Pass flows cut off
B
Pilot burner put off
C
Combustion air cut off
D
Fuel supply cut off

Soot blowing is done to

A
improve furnace efficiency
B
reduce stack temperature
C
to remove soot deposited on the tubes
D
do all the above

Excess air in the furnace stack is due to

A
poor combustion of the fuel
B
low furnace draught
C
High box temperature
D
Air ingress in the furnace

In fuel oil burner, more of the atomizing steam

A
B
C
D

Less of the consumption of fuel oil

Burner flame will be long
Burner flame will be short
Burner flame will be Smokey

Pilot burner trips on

A
Low pass flow
B
FD fan disch flow low
C
pilot gas pressure low
D
fuel gas pressure low

Maximum coke is removed from heater tubes during

A
Spalling operation
B
steam air decoking
C
On line decoking
D
Water flushing

10

Heater tubes are due for decoking when

A
inlet pressure is more
B
discharge pressure is more
C
skin temperatures are more than limit
D
A and C are true

11.

Total nos of heaters tubes in each pass

A
22
B
25
C
32
D
29

12.

Total nos of heater tubes in EACH radiation zone

A
120
B
110
C
121
D
101

14

Nos. of burners in each zone in crude heaters

A
16
B
18
C
14
D
12

15

Velocity steam is injected into the each furnace coil in FO2 at

A
B
C
D

1 point
2 points
3 points
4 points

16

Emergency steam is injected into the each furnace coil at

A
1 point
B
2 points
C
3 points
D
4 points

17

Number of skin thermocouple in each pass is

A
7
B
3
C
4
D
5

18

Nitrogen leak test facility is provided in the BMS for

A
Pilot gas header
B
Fuel Gas header
C
Fuel Oil Header
D
Non of the above

19

Velocity steam to the coil should vary as

A
Increase with the increase in pass flow
B
Decrease with the decrease in pass flow
C
Increase with the decrease in the pass flow
D
All the above

20

First step to take when heater trips

A
Open emergency steam to coil
B
Close all the FO/FG burners valves
C
Reset FG?FO SDV
D
Purge the furnace

21

Furnace is efficient when oxygen in stack is

A
<3%
B
<5%
C
7%
D
>3%

22

In the event of high skin temperature

A
Increase pass flow
B
Decrease pass flow
C
Increase combustion air

Decrease combustion air

23

Stack temperature is low but the oxygen content in flue gas is high means
A
Excess of combustion air
B
Incomplete combustion of fuel
C
Leakage in radiation zone
D
Leakage in convection zone

24

ID fan tripping will result in

A
Furnace tripping
B
FD fan tripping
C
Stack damper opening
D
Non of the above

25

During heater in normal operation, pilot burners of a pass trip on low pressure
A
Main burners in all the four passes will trip
B
Main Burners in that particular pass will trip
C
simply alarm will come and heater will continue to run
D
Non of the above

31

ESD stands for

A. Energy supply Distribution
B. Emergency shut down
C. Emergency steam distribution
D. Equipment shut down.
Fuel Gas Pressure at the Pilot burner should be
A
3.5 kg/cm2
B
4.0 kg/cm2
C
4.5 kg/cm2
D
2.5 kg/cm2

32

33

Crude heater are designed to operate on

A
Forced Draft
B
Balanced Draft
C
Induced Draft
D
Both 1 & 2
E
both 2 & 3

34

Each crude heater has __________ no of soot blowers

A
12
B
14
C
18
D
16

35

Excess temperature in Furnace stack is due to

A
Low Furnace draught
B
FD Fan Trip
C
ID Fan Trip
D
Combustion air cut off

36

Furnace stack gives out smoky flue gas due to

A
Insufficient Fuel
B
Insufficient Air
C
High Draft
D
None of the Above

37

HP Steam Flow rate is measured using

A
Wedge Flow meter
B
Vortex Flow meter
C
Orifice meter
D
Venturi meter

40

When Pass flow value goes down

A
Velocity steam flow increases
B
Velocity Steam flow Decreases
C
Velocity steam flow remains same
D
None of the Above

41

Stack Damper during normal operation is in

A
Fully open position
B
Fully Closed position
C
Semi open position
D
None of the Above

45

Individual heat pass process fluid flow must be

A
>15 m3 / hr
B
>24 m3 / hr
C
>30 m3 / hr
D
>35 m3 / hr

46

Excess air should not be more than

A
20 %
B
28 %
C
30 %
D
10 %

48

Coke build up in the heater tube is indicated by high vale of

A
Skin Temperature
B
Inlet Pressure
C
Fuel Consumption
D
All the Above

49

Stack temperature should be

A
>177 oC
B
>225 oC
C
<225 oC
D
Both A and C

50

Fuel mixture is said to be too rich when

A
Fuel / O2 Ratio is High
B
Fuel / O2 Ratio is Low
C
O2 / Fuel Ratio is High
D
None of the Above

51.

Maximum allowable pressure drop in the heater tube

A
28 kg/cm2
B
25 kg/cm2
C
30 kg/cm2
D
18 kg/cm2

52.

Design Efficiency of heater is

A
93%
B
99%
C
88%
D
82%

53.

Design process Tube temperature

A
540OC
B
641OC
C
662OC
D
592OC

55.

Stripping steam superheating tube has _____ no of flow passes

A
1
B
4
C
2
D
3