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Answer: In an impulse turbine, the stage is a set of moving blades behind the
nozzle. In a reaction turbine, each row of blades is called a "stage." A single
Curtis stage may consist of two or more rows of moving blade.
What is a diaphragm?
Answer: In a radial-flow turbine, steam flows outward from the shaft to the
casing. The unit is usually a reaction unit, having both fixed and moving blades.
They are used for special jobs and are more common to European
manufacturers, such as Sta-Laval (now ABB).
Answers:
1.Carbon rings fitted in segments around the shaft and held together by garter or
retainer springs.
2.Labyrinth mated with shaft serrations or shaft seal strips.
3.Water seals where a shaft runner acts as a pump to create a ring of water
around the shaft. Use only treated water to avoid shaft pitting.
4.Stuffing box using woven or soft packing rings that are compressed with a
gland to prevent leakage along the shaft.
Answer: Tip leakage is a problem in reaction turbines. Here, each vane forms a
nozzle; steam must flow through the moving nozzle to the fixed nozzle. Steam
escaping across the tips of the blades represents a loss of work. Therefore, tip
seals are used prevent this.
Answer:
1.Radial - clearance at the tips of the rotor and casing.
2.Axial - the fore-and-aft clearance, at the sides of the rotor and the casing.
Answer:
1.Babbitt-faced collar bearings.
2.Tilting pivotal pads.
3.Tapered land bearings.
4.Rolling-contact (roller or ball) bearings.
Answer: Thrust bearings keep the rotor in its correct axial position.
Answer: Reaction turbines have axial thrust because pressure on the entering
side is greater than pressure on the leaving side of each stage. To counteract this
force, steam is admitted to a dummy (balance) piston chamber at the low-
pressure end of the rotor. Some designers also use a balance piston on impulse
turbines that have a high thrust. Instead of piston, seal strips are also used to
duplicate a piston's counter force
Why should a steam or moisture separator be installed in the steam line next to a
steam turbine?
What are some conditions that may prevent a turbine from developing full power?
Answers:
1.The machine is overloaded.
2.The initial steam pressure and temperature are not up to design conditions.
3.The exhaust pressure is too high.
4.The governor is set too low.
5.The steam strainer is clogged.
6.Turbine nozzles are clogged with deposits.
7.Internal wear on nozzles and blades.
Why is it necessary to open casing drains and drains on the steam line going to
the turbine when a turbine is to be started?
Answers:
To avoid slugging nozzles and blades inside the turbine with condensate on start-
up; this can break these components from impact. The blades were designed to
handle steam, not water.
Answer: The steam rate is the pounds of steam that must be supplied per
kilowatt-hour of generator output at the steam turbine inlet.
Answers:
1.Impulse type.
2.Reaction type.
Answer: The basic idea of an impulse turbine is that a jet of steam from a fixed
nozzle pushes against the rotor blades and impels them forward. The velocity of
the steam is about twice as fast as the velocity of the blades. Only turbines
utilizing fixed nozzles are classified as impulse turbines.
Answer: A reaction turbine utilizes a jet of steam that flows from a nozzle on the
rotor. Actually, the steam is directed into the moving blades by fixed blades
designed to expand the steam. The result is a small increase in velocity over that
of the moving blades. These blades form a wall of moving nozzles that further
expand the steam. The steam flow is partially reversed by the moving blades,
producing a reaction on the blades. Since the pressure drop is small across each
row of nozzles (blades), the speed is comparatively low. Therefore, more rows of
moving blades are needed than in an impulse turbine.
Answer: This unit has the ends of the Babbitt bearing extended radially over the
end of the shell. Collars on the rotor face these thrust pads, and the journal is
supported in the bearing between the thrust collars.
Answer: The babbitt face of a tapered-land thrust bearing has a series of fixed
pads divided by radial slots. The leading edge of each sector is tapered, allowing
an oil wedge to build up and carry the thrust between the collar and pad.
1. List three scale forming compounds and the type of scale they form (hard, soft,
and insoluble).
5. During rounds of a large generating station you notice the thrust bearing
temperature has increased from its normal temperature of 130F to 145F. All the
other parts of the turbine system are normal. is there a problem, and what do you
do?
7. Draw a picture of a cross compound turbine and indicate all the staging.
8. A flue gas analysis showed 15%co2 and 5% o2, by volume, whats the excess
air?
11. What is an accumulation test? and when should one never be performed?
12. Explain a zeolite water softener process?
13. What is the maximum amount of carbon that can be in boiler pressure part
metal?
14. When steam passes through a P.R.V. what happens to the temperature,
pressure, entropy, enthalpy, and superheat?
15. What flue gasses are measured to control pollution instead of for combustion
efficiency?
16. Name the parts that make up a large surface condenser? (Theres 7 items)
20. How do you know when a shell and tube feed water heater is leaking in the
tubes?
1. Who can adjust safety valves settings and how can you tell if it alright to put
in service?
6. Which clearance is more vital in a reaction turbine axial or radial and why?
11. What are the reasons for superheater failure? Give measure to prevent
these failures.
12. A steel bean 33 long and the temperature is raised 50 degrees C, how long
will the beam be after expansion? Assume expansion is 10 x 10 - 6.
13. During turbine warm up should the vacuum be maintained high or low and
why?
14. What is the furnace heat release 15 x 10 x 46, fuel rate 90gpm and 146,000
Btus/gal?
16. A 200 MAWP boiler has 3 safety valves, what is the range of these valves?
1. A boiler rated for 150,000 Lb of steam per hour only delivers 135,000 Lb of
steam give four possible causes.
2. Define net positive suction head what is the difference between required
NPSH and available NPSH.
4. What is a non-destructive test? give some examples What do the NDT look
for? (this was a welding question)
8. What is the efficiency of this boiler 10,000 Lb steam 150 psi quality 100%
feedwater temp 212 700 gallons of oil burnt in an hour 18,000 btu/gallon enthalpy
of steam 1,151.3
13. Define BLOW DOWN as applies to safety valves Who can adjust blow down
on a safety valve What is the minimum and maximum range of blowback on a
natural circulation boiler. What is the plus or minus on the popping pressure of a
safety valve on a 250 MAWP boiler?
15. Dimensions of a furnace given and gallons of oil per minute burned and Btu
content give the furnace heat release.
18. What type of turbine develops more end thrust impulse or reaction and why?
12. What are the blow down requirements for a 150 MAWP boiler for both piping
and valves?
13. Define BLOW DOWN as applies to safety valves Who can adjust blow down
on a safety valve What is the minimum and maximum range of blowback on a
natural circulation boiler. What is the plus or minus on the popping pressure of a
safety valve on a 250 MAWP boiler?
15. Dimensions of a furnace given and gallons of oil per minute burned and Btu
content give the furnace heat release.
a. Sodium Sulfite
b. Sodium Hydroxide
c. Sodium Chloride
4. What does bleed steam do for turbine efficiency when bleeds are used as
feed water heaters?
5. Oil weighs 6.91 lb/gal with 39 API specific gravity. Whats lb/ft3 ? How
many barrels are there in 100 tons? (Note 1 gal of water weighs 8.33 lb)
6. A question that asks about throttle valves and nozzles . I think it was
looking for throttling losses and why is it better to control steam flow with nozzles.
a. Main condenser
b. Aux condenser
14. What is the main purpose of a hole bored in the center of a turbine shaft?
15. A question that asks how you check a weld after post heat treatment?
16. Calculate the heating value for 85% carbon, 5% hydrogen, 5% oxygen, and
1% sulfur.
17. If condenser tubes are rolled at each end how does expansion occur?
d.
18. Impulse or reaction turbine? Which one weighs less and is smaller per
mechanical horsepower produced?
1. What is a steam boiler under ASME code as far as pressure and temp?
5. A boiler rated for 150,000 lbs/hr and is putting out 130,000 lbs/hr. Give 4
reasons why its not putting out its max.
11. Calculate the combustion air require for 10% carbon, 5% Hydrogen, 5%
Oxygen and 3% Sulfur.
12. What is an adiabatic process and where does it take place in a power plant?
13. A boiler generates 10,000 lbs of steam per hour and has a factor of
evaporation of 1.24, what is the developed boiler horsepower?
15. How much can a 250 lb safety valve be adjusted above or below set
pressure? Who can adjust the safety valve?
16. Has an authorized inspector any right to disagree with the manufacturers
records and call for re qualification of a welder or to have physical test made
again?
Sodium hydroxide?
Sodium sulfite?
Sodium chloride?
1. According to M.G.L. Chapter 146, Section 34, how often should air tanks be
inspected? What pressure should they be inspected?
10. On some turbines, why are there more than one steam inlet lines?
12. A question of a fuels but per/lb burning 82% efficient, using an amount of
fuel in lb/hr. What was the btu loss?
13. What boilers come under the ASME Power Boilers Section 1.
16. If the condenser tubes are rolled at each end, what takes the expansion on
the condenser. (This was a multiple choice question)
17. You need a turbine, 40 pounds and a large volume of steam and exhaust to
a condenser. What type of turbine are you going to order.
2. Required oil pressure at bearing is 8 psig. Oil tank is 20 feet above. Is oil
pressure enough. S.G is .75.
16. 2" pipe supplying steam. Pipe is increased to 6". How much more steam?
19. Blow down pipe and valve requirements for 150 psig boiler.
20. Napiers law: W=51.5 AP. Given steam flow (W), and pressure is 400psia
what is the required safety inlet diameter.
5. What are the three main areas of concerns when it comes to stress when
determining the working pressure of a fire tube boiler
9. How would you detect a leak in a closed loop feed water heater?\
10. Where does steam turbine blade erosion occur, what causes it?
14. What qualifications must you have to sit for this license?
15. You are purchasing a 10,000,000 BTU boiler for use in MA, according to
CMR what environmental controls will be required?
16. How are flame monitors positioned in reference to igniters and why?
19. After repairing an inverted bucket trap, what is the first thing you do before
placing it back into service?
8) You need to order a safety valve for a new boiler what do you need to
know?
11) What prevents a turbine from overspending from the steam in the reheater
after a trip?
13) What does dissolved oxygen do in a boiler, how do you prevent it?
16) What causes corrosion and pitting? How do you prevent it?
19) On a boiler, the manufacturers data plate states that it produces 345 #/hr,
the owner requests that a second data plate be installed which states the HP is
8.5, and that it has a BTU input of 356000 BTUs. Which one is correct?
2) What is a shroud?
3) Blade speed of turbine is 400 RPM and blades are 48. Steam speed is
11500 ft/min. What is relation between blade speed and steam speed?
5) Explain procedure for blow down of a boiler with one quick opening valve
and one slow opening valve. Explain the difference between blowdown and blow
off systems.
6) What is a watt?
10) How do you remove a poor weld that needs to be done over?
11) How do superheater tube failures occur? How do you prevent these
problems?
13) A steel beam is 33 ft. long and the temperature is raised 50 degrees C. How
long will the beam be after expansion? Assume expansion coefficient is 10 X 10
to the -6th power.
14) Does bleeding steam from a turbine for pre heating affect turbine efficiency?
15) Which part of the boiler receives the most pressure?
18) Pump 1 can empty a tank in 6 hours. Pump 2 can empty same tank in 5
hours. How long will it take to empty the same tank using both pumps at the
same time?
1. Why does the auxiliary oil pump run after the turbine has been shut
down and secured.
11. How is turbine connected to a feed pump, and explain how to align.
2) What is the main purpose of a hole bored in the center of a turbine shaft?
8) Who is authorized to adjust safety valves and how can you tell if a safety
valve is alright to install?
10) You are on watch at your plant, turbine is off line and on the turning gear,
when can you close the generator breaker and why?
13) What does the commonwealth require of a person performing the duties
of the engineer in charge of a second class plant, what license is required?
14) List four things that would cause a turbine to appear unbalanced when it
actually was balanced?
15) What is a blow down tank and what the piping requirements?
20) What happens to the latent heat as the pressure goes up?
1. Name three ways that expansion and contraction of rotor and casing are
handled at the H.P. End of the turbine?
2. How is over speeding of a turbine that has a reheater prevented after the
turbine has tripped?
9. In a surface condenser, how can you tell if vacuum loss is due to air
infiltration or a dirty condenser?
12. In a combined cycle gas turbine plant, what major maintenance repair is
done to fix compressor fouling?
13. In a combined cycle gas turbine plant, what major operation procedures can
be done to prevent compressor fouling?
14. A new boiler in your plant has a tag on it that states it has 65 sq. ft. heating
surface and operates at 345 #/hr, it has an s stamp and a national board
number. The installer attaches a new tag that says the heating surface is 50 sq.
ft. and has a Btu input of 300,000 + Btu/hr (not sure of exact number). As chief of
this plant, what is real hp and how do you know which tag is correct? (Chapter
146).
17. You come across a thrust bearing that is reading 145F where normally it
has been 130F. what do you do?
3.) You have 52 barrels of fuel oil with a specific gravity of .85. What does the
fuel weigh? (1 gallon of water weighs 8.33 lbs).
4.) What does ANSI 31.1 say about blow off valves and piping on a boiler with
an M.A.W.P. of 125 PSI?
5.) What is the factor of safety of a boiler with an M.A.W.P. of 275 PSI that has
a safety valve set at 150 PSI? The old factor of safety was 4.
6.) When a process goes through volume and pressure variations but no
temperature changes is called?
8.) Which turbine has more end thrust Impulse or Reaction and why?
9.) What is Water Hammer and how do you prevent it and remedy it?
12.) When a process goes through Volume and Pressure variations but no
temperature change occurs this is known as? (Yes the question was repeated on
the second page of the test).
13.) How do we calculate Turbine horsepower and what is water rate used for?
(Yes, second water rate question).
15.) Calculate the M.A.W.P. for a boiler 60 in diameter, having thick plate,
with a tensile stress of 11,000 and a joint efficiency of 80%? Use p=.8SET/R + 6T
17.) Define the following; Tensile strength, Elastic limit, Yield point, Elongation
and Reduction of area?
18.) A.) What is minimum relieving capacity of an electric boiler operating at 512
Watts?
5. An oil has a weight of 7.398 pounds per gallon. What is the specific
gravity of the oil? Water weighs 8.34 pounds per gallon.
6. Name six losses of a turbine (do not list loss to the condenser).
15. What is Net Positive Suction Head? What is "actual" and "required"?
2. What is the difference. between inner crystalline & trans crystalline cracks in
boiler
4. A horse power of a boiler has a MAWP of 800 psi. what is the minimum
pressure rating required by
5. When are backing rings required by code and can they be left in place or
removed?
6. What is the difference between a once through and a super critical steam
generator? What are the temperature and pressure that define a super critical
steam generator?
8. Explain where you would use the following non destructive exams?
radiography
magnetic particle test
eddy current test
ultra sonic test
11. How are allowances for expansion in steam piping commonly achieved?
Name 3 ways?
13. A boiler has 400 psi on it. it's 2.5"diam. What is the force on the valve disc?
show all work!
15. How do you determine the relieving capacity of a separately fired super
heater?
18. Delong's formula problem. Coal sample taken with all percents given.
11. Safety valves and safety relief valves what are the differences?
12. You have two pumps and one tank, one pump can empty the tank in 6 hours
the other in 5 hours. How long would it take if both ran?
13. You have 52 barrels of #6 oil with a specific gravity of .85 at 60 degrees.
What is the weight of the oil?
15. Are temperature changes or pressures more harmful to a boiler, and why?
16. What is the efficiency of a boiler 150psig 100% quality, 10,000 lbs /hr fuel 700
lbs, 18,000 btu lb.
5. What two adjustments can be made on a safety valve, and who can do
it?
6. A.) How do you know a welder is qualified? B.) How long does the
qualification last? C.) Who keeps records and is responsible for testing?
7. Find the BTU content of a coal sample with, c 85%, 02 5%, H 5%, S 1%
N 3%, A 1-%?
8. Who tests the coupons sent in by the welders?
13. A boiler fired with coal with a BTU value of 18,500 per lb. burning 1150
lb./hr at 82% efficiency what is the total BTU loss'?
14. State the procedure for blow down tank installation? Explain fully.
15. The company with a spool piece has reduced a turbine with a six-inch
inlet to four inches. Who can operate and take charge this turbine in accordance
with chapter 1467
5. Blades 48in., 400RPM, What is the steam speed in relation to blade speed
with steam traveling @ 11,900 ft/min?
6. 6 inch inlet company wants to install a 4 inch. spool who can have charge of
this according to Chap. 146?
9. What are the duties of an engineer in charge? What license do you need if it's
a 2nd class plant?
13. Fans Laws: Fan speed increases, What happens to the volume of air, total
pressure, and horsepower?
14. How would you figure safety valve relieving capacity on a super heater?
3. How long must the radiographs be kept on file by the manufacturer for power
boilers?
4. How do you align the shaft of a small turbine feed pump and explain how to
check it?
5. Give 3 ways you can tell the bearings on a turbine are overheated.
6. Why does the auxiliary lube oil pump continue to operate even after the turbine
has been secured?
8. A boiler generates 20,000 lb/hr and has a factor of evaporation of 1.24. What is
the developed boiler horsepower?
11. How is scrap metal prevented from entering the pulverizer when burning
pulverized coal?
12. Define net positive suction head. What is required and actual net positive
suction head?
13. Describe thermal efficiency of a turbine with bled steam heating feed water
at various stages.
14. List the steps for starting a turbine driven feed water pump.
18. Describe the operation of a Hydraulic Governor be very clear and specific
use a drawing if necessary.
19. Surface condenser vacuum is 27" the barometer reads 29.8". What is the
absolute barometric pressure and absolute psi.
1. Match the terms with the definitions. All definitions given. A. Erosion, B.
Corrosion, C. Enthalpy, D. Entropy, E. Tensile strength, F. Tensile stress, G.
Fatigue, H. Fracture.
8. What is the popping point tolerance for a 250lb. Steam safety valve?
9. A picture of a thrust bearing, what kind is it? And describe its construction
and operation.
10. What are six ways a surface condenser will gradually loose vacuum?
11. On a turbine, the control valves are operated by a beam driven by a cam
gear. How does this reduce throttling losses explain fully?
12. Explain what happens to the steam pressure and velocity in each part of a
velocity compound Curtis Stage?
13. The third law of Thermodynamics is. A. Newton's Law, B. Boyls Law, C.
Charles Law, D. Boltzmens Law.
14. Who is qualified to change the set pressure on a steam pop safety valve?
15. Can a qualified welder do any welding repair on a boiler? Explain fully.
17. What would cause a turbine shaft to be bowed? A. Turning gear binding, B.
Improper cool down of the turbine, C. D.
18. How much expansion on a beam 33 feet long 50 degree Celsius raise
coefficient is ten times ten to the negative six?
19. What is the BDHP with steam at 1200 btus. 150,000 steam flow, and feed
water 230 degrees. Factor of evaporation is not known.
20. A boiler generates 5,000,000 lbs. Of steam per day. The CBD blowsdown
5%. The temp of the feed water is 400 degrees. How much water is blown down
per day, and what is the BTU loss?
5. A boiler is rated for 150,000 pounds of steam per hour, but only produces
135,000 pounds per hour. List four (4) probable causes.
6. A turbine operates at 100% efficiency. The steam is supplied at 175 psig,
exhausts at 28.5 inches Hg. The turbine uses 1,000 pounds of steam per hour.
What is the horsepower and water rate? (Given h1=1,197; h2=851; hf2=105).
8. What information is listed in the Daily Record book that is published by the
Massachusetts Department of Public Safety?
11. What is the theoretical discharge pressure of a pump from 1,800 RPM at 100
PSI to 3,000 RPM?
13. Name at least six turbine losses? Do not use the condenser in your answer.
14. Name five reasons for a pressure drop in a Number 6 fuel oil line.
16. There are two 300 HP boilers in separate locations in the same plant. Can a
third class engineer take charge? If the boilers are in battery?
17. A Company wants to insert a spool piece to change the steam inlet to the
turbine from 6 to 4. What license is necessary to be in charge?
19. What is the purpose of a vacuum pump in a vacuum heating system and
why is such a heating system used?
1.) What is the efficiency of this turbine using the Rankine Cycle? 200 PSIA,
600o F, 1" back pressure, rated at 10.5 per horse power hour.
2.) How many expansions take place with steam at the following conditions?
Steam pressure 400 PSIA & Vacuum 29 ". Steam tables given.
3.) A boiler burns #6 fuel oil with a heating valve of 146,000 BTU's a gallon.
Steam at the boiler outlet has 1200 BTU.s, feed water temperature is 210o F .
Combustion efficiency is 82 %. How many lbs of water can be evaporated per
gallon of fuel?
8.) Find the thickness of a head with the pressure on the concave side when it is
the segment of a sphere with a flanged in manhole? Given: 300 MAWP, 40"
Diameter, Stress = 13,700, PG 29.3 states thickness shall be increased by 15%
9.) How can a boiler tube carry such high pressure with such thin walls? Prove
by this formula for a longitudinal
10.) Given the pitch the tube diameter and hole diameter. What is the ligament
eff?
12.) What is the ASME Code for (boilers) and what is the National Board for?
13.) Name four causes of loss of vacuum and how to correct them?
14.) How much heat is lost to the condenser given the following? Given: Inlet
pressure & temperature, vacuum, barometer and they gave a figure of 1050
BTU's at exhaust.
16.) What is the purpose of a extraction turbine grid valve? Explain fully.
17.) A turbine uses 40,000 lbs of steam a hour and a output is 2,000 KWH. What
is the water rate?
18.) With respect to corrosion deterioration, what is grooving and where would
you find it?
3.) What is an Exciter? What is it's purpose and what would happen if you lost
excitation?
4.) Xfoliatio, what is it? Explain fully. What does it affect? What problems would
it pose?
5.) Safety valve nozzle reaction type, what would happen should the orifices
become obstructed?
6.) How may corrosion around manholes and hand holes be repaired? What are
the limits?
11.) How come a non-condensing turbine will show a higher efficiency than a
condensing turbine?
12.) A coal bunker contains 20,500 ft3 of coal. What is the weight of the coal in
pounds?
13.) A steam supply line is to carry 10,000 lbs / stm / hr @ 200 psi, the volume of
the steam @ 200 psi is 2.2893 ft3, what is it's velocity? What diameter of pipe
would be required?
14.) How would you figure the ratio between a reaction vs. Curtis stage in a
turbine?
15.) A boiler contains 500 water wall tubes, each tube is 20 ft long and 4 inch
diameter. The convection section contains 1200 tubes 4 inch by. What is the
heating surface in ft2
18.) 500 lbs of water @ 1500 and 300 lbs @ 900 are mixed together, what is the
final temperature of the mixture?
19. Why are welded joints stronger than the metals they have joined? What
happens during the welding process?
20.) Steam pressure at a turbine inlet is 950 Pisa it exhaust to the condenser @
1.5" hg. What is the number of expansions?