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Energy Plant Maintenance Comprehensive
Study Guide with Key Concepts and 260
Practice Questions and Answers 2025
Adjustable wrenches should only be used : A ) With the turning force applied to the fixed jaw B ) On piping C ) With a universal joint D ) With the turning force applied to the moving jaw E ) To tap threads - ✅ A A screwdriver having a square tip is known as : A ) A slot B ) A Jacobson C ) A Robertson D ) A Phillips E ) An Allen - ✅ C Whatever the size of a micrometer , the working parts can only move a distance of : A ) 30 mm B ) 200 mm C ) 25 mm D ) 300 mm E ) 250 mm - ✅ C To measure valve tappet clearances , one would most aptly use : A ) A depth micrometer B ) Round or fillet gauges C ) A thread micrometer D ) An inside micrometer E ) Feeler gauges - ✅ E Taper , plug and bottoming are types of : A ) Dies B ) Punches C ) Files D ) Taps E ) Wrenches - ✅ D Hand taps are usually made in sets of three called : A ) Primary , secondary , and finishing B ) SAE , ISO , Metric C ) Taper , plug , and bottoming D ) Warding , mill , and bastard E ) Rough , coarse , and fine - ✅ C An important safety check when using any grinder is to ensure : A ) The grinder is designed for right handed people B ) The guard is removed C ) Wheel speed is correct D ) The power is turned on E ) The grinder is light weight - ✅ C
Chalk or may be used to rub on the surface of rough castings as a marking material. A ) Aluminum sulphate B ) Wax C ) Blue vitriol D ) Grinding compound E ) Soap stone - ✅ E In general hacksaw blades used on thin metal : A ) Have coarser teeth B ) Are thinner Are made of flexible steel D ) Are painted orange E ) Have more teeth - ✅ E Micrometers are available in a variety of types and are used mainly for the measurement of : A ) The density of the boiler flue gases for pollution control B ) Outside , inside , and depth dimensions of relatively small openings of objects Vertical , perpendicular and parallel distances in assembly of power plant machines D ) Length , width , and thickness of the boiler house structure E) Dissolved solids in boiler water - ✅ B A tap with the marking M4 would indicate a : A ) Tap with metallic threads B ) Metric thread , 4 cm nominal diameter of the thread C ) Metric thread , 4 mm nominal diameter of the thread D ) Metric thread E ) Metric thread , 4 threads per mm - ✅ C To shear old bolts or split nuts , you would select : A ) A diamond point chisel B ) A hacksaw C ) A ball peen hammer D ) A rasp E ) A flat chisel - ✅ E When drilling speed is too fast , it results in : A ) The hole will be too deep B ) The drill bit will get struck and break C ) The metal will melt D ) The drill bit will fail due to centrifugal forces E ) It will dull the - ✅ E When using a file properly : A ) No force is required B ) Apply force on the back stroke C ) Avoid using a handle D ) Apply force on the forward stroke only E ) Apply force in both directions - ✅ D
Steam boilers on standby that are layed up with water in them , should have their pH adjusted to : A ) 5.5 B ) 12 C ) 7 D ) 8 E ) 10 - ✅ E When boilers are layed up for long periods in freezing conditions , the chosen method is usually : A ) Heated layup while maintaining a pilot B ) Dry layup C ) Wet layup D ) Wet layup with antifreeze E ) Dry layup with a small flame to maintain temperature above freezing - ✅ B When a boiler is locked out by a competent operator : A ) Maintenance activities can proceed immediately B ) It must be approved by an inspector C ) The plant manager must double check the procedure D ) A second competent operator must verify correctness E ) The safety department must verify the correct type of locks are used - ✅ D A boiler on wet layup should maintain a nitrogen blanket of : A ) 40 kPa B ) 100 kPa C ) 10 Kpa D ) 0 kPa E ) 200 kPa - ✅ A During the summer layup period , hot water boilers are usually : A ) Kept full of chemically treated water B ) Refilled with fresh municipal water C ) Maintained full of caustic soda D ) Drained and dried out E ) Dismantled and dried - ✅ A Blowdown on steam boilers is increased before shutting down to : A ) Discharge sediment and sludge B ) Make room for fresh water and chemicals C ) Lower the boiler level D ) Test the level controls E ) Verify the low level shutdown - ✅ A Wet layup of steam boiler that are being kept out of service for a period of time , but must remain ready to be put back online with short notice should : A ) Maintain the boiler completely full of water to prevent oxygen from entering the boiler B ) Kept running at all times C ) Dismantled and new parts ordered D ) Should be layed up dry E ) Be drained completely and dried out - ✅ A
When preparing to remove a hot water boiler from service , all of these are done prior to closing the fuel gas valve except : A ) Blowdown the boiler to remove sediment B ) Perform a try lever test on the safety relief valve C ) Lock out the boiler draft fan D ) Test operating and limit controls E ) Test the water chemistry - ✅ C When a competent operator shuts down and locks out a boiler , they will : A ) Lock out the water and steam systems only B ) Only lockout the steam system C ) Follow manufacturers recommendation only D ) Use double locks on all gas lines E ) Follow site specific procedures - ✅ E Boilers that are on shutdown on standby are usually layed up using the. ‒‒‒‒‒ method. A ) Hot standby B ) Dry layup C ) Drained and hot D ) Maintained at full pressure E ) Wet layup - ✅ E When preparing to remove a hot water boiler from service , all of these are done prior to closing the fuel gas valve except : A ) Blowdown the boiler to remove sediment B ) Perform a try lever test on the safety relief valve C ) Lock out the boiler draft fan D ) Test operating and limit controls E ) Test the water chemistry - ✅ C Wet layup of steam boiler that are being kept out of service for a period of time , but must remain ready to be put back online with short notice should : ✓OA ) Maintain the boiler completely full of water to prevent oxygen from entering the boiler B ) Kept running at all times C ) Dismantled and new parts ordered D ) Should be layed up dry E ) Be drained completely and dried out. - ✅ A A boiler on wet layup should maintain a nitrogen blanket of : A ) 40 kPa B ) 100 kPa C ) 10 Kpa D ) 0 kPa E ) 200 kPa - ✅ A When boilers are layed up for long periods in freezing conditions , the chosen method is usually : A ) Heated layup while maintaining a pilot B ) Dry layup C ) Wet layup D ) Wet layup with antifreeze E ) Dry layup with a small flame to maintain temperature above freezing - ✅ B
A device found on the pressure side of a steam boiler operating control switch is a : A ) Test connection for an inspector B ) Feedwater pressure gauge C ) Siphon D ) Combustion air proving switch E ) Modutrol motor - ✅ C A hot water boiler operating control can be a pressure switch : A ) Which is sensitive to the expansion and contraction of boiler water B ) Sensitive to boiler steam pressure C ) Which is normally open D ) Utilizing a closed liquid filled system E ) Sensitive to steam pressure - ✅ D On hot water heating boilers , a high limit temperature control switch : A ) Is necessary on all boilers B ) Usually does not require manual resetting C ) Activates after the safety valve opens D ) Must be installed on automatically fired boilers E ) Is a normally open switch - ✅ D Hot Water heating boilers with fully modulating burners require : A ) Modulating Level control B ) Back up on - off control C ) Modulating pressure control D ) Modulating flow control E ) Modulating temperature control - ✅ E Modulating burner controls operate by regulating : A ) Fuel flow and atomizing steam flow B ) Fuel temperature and air flow C) Steam flow and fuel flow D ) Fuel flow , air flow , and feedwater pressure E ) Fuel flow and air flow - ✅ E The controlled variable in heating boilers with modulating control cause a bellows to operate a : A ) Hydrostat B ) Shut down valve C ) Alarm D ) Mercury switch E ) Potentiometer - ✅ E A thermal element is : A ) Used to measure heat content B ) A type of open system C ) Commonly termed an " Aquastat " D ) Capable of sensing temperature and converting it to a pressure signal E ) Used to measure pressure - ✅ D
The operating cut off for low pressure steam heating boilers should be set at : A ) 70 kPa B ) 115 kPa C ) 35 kPa D ) 100 kPa E ) 45 kPa - ✅ A The type of combustion fuel control frequently used on a smaller package boiler , is a / an : A ) Scanner B ) Constant pressure control C ) On and off control D ) Modulating control E ) High fuel level cut - off - ✅ C An Aquastat : A ) Can be located away from its point of measurement B ) Is a modulating device C ) Measures water flow D ) Senses water level E ) Is used on steam boilers - ✅ A Positive displacement compressors : A ) Could be single stage with three cylinders B ) Could be of the centrifugal type C ) Must all use internal lubrication D ) Must all use cylinder valves E ) Require a positive water seal - ✅ A In a centrifugal compressor the kinetic energy is converted to potential energy in the : A ) Intercooler B ) Volute only C ) Volute , diffuser or both D ) Diffuser only E ) Compressor cavity - ✅ C The two types of dynamic compressor are centrifugal and : A ) Screw B ) Axial C ) Gear D ) Scroll E ) Lobe - ✅ B The valves on a reciprocating compressor are opened by : A ) The eccentric B ) A pressure difference C ) A timing gear D ) The camshaft ) Hydraulic pressure - ✅ B Air compressors that supply instrument air should : A ) Have turbine drivers B ) Have air intake far from sources of exhaust C ) Not be used for any other purpose D ) Be located on the roof E ) Always be positive displacement - ✅ B
In order to keep rope from untwisting under load : A ) Rope thimbles should be used B ) It requires a synthetic binder C ) Each end requires " whipping " D ) It should be moistened E ) It is made with left and right handed counteracting twists - ✅ E Stove bolt nuts are usually : A ) Left hand thread B ) Hexagonal Self locking D ) Fine thread E ) Square
- ✅ E The top of a ladder should extend approximately. above the level of the upper landing to which it provides access. A ) 1.0 m B ) 2 m C ) 0.2 m D ) 0.3 m E ) 0.5 m - ✅ A Castle nuts are used : A ) With a split pin B ) To hold shims in place C ) For locking square nuts in place D ) To lock the bolt in place E ) With a square pin - ✅ A Electricians prefer fiberglass ladders because : OA ) They are stronger ) They are more compact C ) They come in longer lengths OD ) They are lighter E ) They do not conduct electricity - ✅ E Prior to hoisting an object it is very important to : A ) Measure the width B ) Measure its length C ) Attach at least two slings D ) Know or calculate the mass E ) Know the route required - ✅ D Machine bolts are commonly supplied with : A ) Pan heads B ) Square heads C ) Truss heads D ) Hexagon heads E ) Oval heads - ✅ D Wire rope classified as 8 x 12 means it has : A ) A factor of safety of 8 and is 12 metres long B ) 8 strands with 12 wires per strand C ) 12 strands with 8 wires per strand D ) A factor of safety of 12 and is 8 metres long E ) None of the above - ✅ B
Platforms should have a edge going around them to prevent objects from rolling off. A ) Raised B ) Wire C ) Square D ) Magnetic E ) Metal - ✅ A Lock washers : A ) Prevent unwanted turning of the bolt or nut B ) Distribute the lock nut force C ) Prevent anyone from dismantling the object D ) Allow oversized bolts or nuts to be used E ) Prevent marring of the work surface - ✅ A An M24 coarse thread bolt has : A ) 3 threads per mm B ) 2 mm per thread C ) 3 mm per thread D ) 3.5 threads per mm E ) 3.5 mm per thread - ✅ C A knot used to pull at right angles to a pipe or pole is the : A ) Clove hitch B ) Reef knot C) Timber hitch D ) Bowline E ) Round turn and two half hitches - ✅ A When joining two ropes of different diameters , we use a : A ) Round turn and three half hitches B ) Figure eight knot C ) Reef knot D ) Sheep shank E ) Sheet bend - ✅ E The mechanical fastener used in the assembly of automotive and plant machinery is the : A ) Machine screw B ) Stove bolt C ) Carriage bolt D ) Machine bolt E ) Cap screw - ✅ D A strand of fiber rope is : A ) The most important part of the rope B ) Composed of fibers twisted right - handed C ) The smallest component of the rope D ) At least 20 metres in length E ) Composed of yarns twisted left - handed - ✅ E A yellow scaffold tag indicates : A ) The scaffold is safe to use but there are hazards B ) The scaffold is unsafe C ) The scaffold is almost unsafe to use D ) The scaffold is only safe for 1 person at a time E ) The scaffold needs repair - ✅ A
A boiler circulating pump gland should have some leakage : A ) In order to keep the motor amperage down B ) To prevent the packing from drying out C ) So that the shaft sleeve will take the wear D ) In order for the stuffing box to run at the desired high temperature E ) So the operator can tell when the pump becomes vapour bound - ✅ B It is recommended that a new boiler be shut down , drained , opened up , flushed out and inspected after the first ________ months of operation. A ) Six B ) Twelve C ) Three D ) Two E ) Nine - ✅ C When the fireside of a boiler is first opened up , small leak seepage spots can be detected by : A ) Hissing sounds B ) Water on the furnace floor C ) White salt deposits resulting from water evaporation D ) Water running down the tubes E ) Ultraviolet light - ✅ C A tube expander is used for : A ) Repairing cracks in leaking tube B ) Expanding the tube end ) C) Making the tube longer D ) Bending tubes E ) Making the tube stronger - ✅ B Boiler furnace refractory should be to prolong its life. A ) Oiled to prevent corrosion B ) Painted with heat resistant paint C ) Wire brushed D ) Washed with a high - pressure hose E ) Wash coated with a dilute solution of heat resistant cement - ✅ E A water tank should be installed above the boiler and attached to the vent connection during a wet lay up in order to : A ) Prevent water vapour from entering the power plant B ) Hold the manway doors closed C ) Prevent air from entering the boiler during water contraction D ) Permit the injection of chemicals. E ) Prevent the wastage of chemicals - ✅ C Boilers that are maintained on hot standby should be : A ) Left with a fire in the furnace B ) Dried out on the water side C ) Nitrogen capped D ) Steam capped E ) Drained - ✅ D
The final step in replacing a firetube is : A ) Firing the boiler up to normal working pressure B ) A light re - expansion C ) Filling the boiler with water and checking for leaks D ) Annealing the tube ends E ) Applying a hydrostatic test - ✅ E A ) 1 , 2 , 4 B ) 1 , 2 , 3. C ) 2 , 3 D ) 2 , 3 , 4 E ) 1 , 2 , 3 , 4 - ✅ A The interior of firetubes are cleaned to remove deposits of : A ) Corrosion B ) Salt C ) Algae D ) Scale E ) Soot - ✅ E Laying up a boiler means : A ) Preparing the boiler for a period of storage B ) Preparing a boiler for start up C ) Raising the boiler D ) Setting the boiler on its foundation E ) Taking the boiler down for an annual overhaul - ✅ A A substance that will absorb humidity inside a boiler during dry lay up is : A ) Activated alumina B ) Sodium chloride C ) Zeolite D ) Sodium sulphite E ) Lime soda - ✅ A A tube beading tool is used : A ) To cut fire tubes B ) To unfasten fire tubes from the tube sheet C ) On firetube boilers D ) To fasten the stays in the tube sheet E ) On watertube boilers - ✅ C Who should be responsible for doing frequent boiler inspections? A ) The Boiler Inspector B ) The Owner C ) The Chief Inspector D ) The Insurance Agent E ) The Steam Plant operator - ✅ E Thinning and grooving of metal parts is A ) Carbon Monoxide B ) High Hardness C ) Carbon Dioxide D ) Oxygen E ) Scale - ✅ C
Condensate polishers can control suspended matter , hardess and : A ) Molybdates B ) Sulphites C ) Temperature D ) Dissolved Oxygen E ) Chlorides - ✅ E Just before entering the waterside of the boiler it is important to : A ) Obtain permission to do so from plant management B ) Ensure the Chief Engineer is aware of your intent C ) Notify the inspector in writing of your intent to do so D ) Be wearing self - contained breathing apparatus SCBA E ) Test the atmosphere - ✅ E One of the legal responsibilities of the engineer during an inspection is : A ) To notify the Workers ' Compensation Board of the inspection B ) To be in possession an inspection certificate C ) To allow the inspector onto the premises , but only during working hours D ) Point out any known or suspected defects to the inspector E ) To have at least two staff members present at all times - ✅ D For an alkaline boil out , the boiler is maintained at a desired steam pressure for about : A ) 16 hours B ) 48 hours C ) 24 hours D ) 8 hours E ) 12 hours - ✅ B Chemical cleaning of smaller boilers is not usually done because : A ) They do not have adequate support for the high density of the chemicals B ) Of the small surface area which the chemical contacts C ) It is impossible to get the chemical circulating adequately D ) Of the thin metal of which they are manufactured E ) The cost to do so is not warranted or justified - ✅ E Before cleaning the waterside and as far as is possible : A ) Tubes should be " turbined " B ) A scale sample should be taken and an analysis done C ) All drum internals should be removed D ) Mud drum sludge should be completely removed E ) A visual inspection of pressure parts should be completed - ✅ E A boiler inspection : A ) Is done with the owners permission only B ) Is only required after a boiler has been operating 3 years C ) Must be done whenever the boiler inspector requests it D ) Is only required if an accident occurs E ) Must be done after every shut down of the boiler - ✅ C
The recommended procedures for a boiler inspection are stated in the : A ) ASME Boiler and Pressure Vessel Code , Section I B ) Alberta Pressure Equipment Safety Regulation C ) CSA B51 Boiler Pressure Vessel and Pressure Piping Code D ) ASME Boiler and Pressure Vessel Code , Section VII E ) ASME Boiler and Pressure Vessel Code , Section IV - ✅ D A hydrostatic test on a high pressure steam boiler : A ) Will test the high pressure steam fuel cut off B ) Must only be done by the inspector C ) Must be done according to jurisdictional regulations D ) Must be done before every start up of a boiler E ) Should be done with the Chief Engineer present - ✅ C When the boiler is removed from service , it can be drained once the temperature reaches approximately : A ) 65 ° C B ) 70 ° C C ) 90 ° C D ) 150 ° C E ) 50 ° C - ✅ C A relatively safer chemical used in boiler cleaning and treatment is : A ) Sodium hydroxide B ) Chelates C) Trisodium phosphate D ) Caustic soda E ) Hydrazine - ✅ B An inhibitor , when added to acid will : A ) Make the acid compatible with the sewer system for disposal B ) Cause foaming in the boiler C ) Strengthen the acid thereby shortening the cleaning procedure D ) Prevent the acid from attacking the boiler metal E ) Minimise the effect the acid has on the metal - ✅ E A boiler has been in operation for one year and is now taken off the line for cleaning , repair and inspection. The boiler is one of three in a battery and the other two will remain in operation. This one boiler is to be drained and cooled. Before any person is allowed to enter the boiler drum , the correct safety procedure requires that the : A ) Main steam , blow down , blow off , and feedwater valves be closed , chained and tagged B ) Person is equipped with the correct kind of tools and a list of required repairs C ) Worker is provided with a safety kit for confined space entry D ) Worker is provided with a safety line , first aid kit , and hard hat E ) Drum be vented , the safety valve gagged , and all ashes and soot removed from the fire box - ✅ A
Just before entering the waterside of the boiler it is important to : A ) Obtain permission to do so from plant management B ) Ensure the Chief Engineer is aware of your intent C ) Notify the inspector in writing of your intent to do so D ) Be wearing self - contained breathing apparatus SCBA E ) Test the atmosphere - ✅ E For an alkaline boil out , the boiler is maintained at a desired steam pressure for about : A ) 16 hours. B ) 48 hours C ) 24 hours D ) 8 hours E ) 12 hours - ✅ B Chemical cleaning of smaller boilers is not usually done because : A ) They do not have adequate support for the high density of the chemicals B ) Of the small surface area which the chemical contacts C ) It is impossible to get the chemical circulating adequately D ) Of the thin metal of which they are manufactured E ) The cost to do so is not warranted or justified - ✅ E Before cleaning the waterside and as far as is possible : A ) Tubes should be " turbined " B ) A scale sample should be taken and an analysis done C ) All drum internals should be removed D ) Mud drum sludge should be completely removed E ) A visual inspection of pressure parts should be completed - ✅ E A boiler inspection : A ) Is done with the owners permission only B ) Is only required after a boiler has been operating 3 years C ) Must be done whenever the boiler inspector requests it D ) Is only required if an accident occurs E ) Must be done after every shut down of the boiler - ✅ C The recommended procedures for a boiler inspection are stated in the : A ) ASME Boiler and Pressure Vessel Code , Section I B ) Alberta Pressure Equipment Safety Regulation C ) CSA B51 Boiler Pressure Vessel and Pressure Piping Code D ) ASME Boiler and Pressure Vessel Code , Section VII E ) ASME Boiler and Pressure Vessel Code , Section IV - ✅ D A hydrostatic test on a high pressure steam boiler : A ) Will test the high pressure steam fuel cut off B ) Must only be done by the inspector C ) Must be done according to jurisdictional regulations D ) Must be done before every start up of a boiler ) Should be done with the Chief Engineer present -
✅ C
Question When the boiler is removed from service , it can be drained once the temperature reaches approximately : A ) 65 ° C B ) 70 ° C C ) 90 ° C D ) 150 ° C E ) 50 ° C - ✅ C relatively safer chemical used in boiler cleaning and treatment is : A ) Sodium hydroxide B ) Chelates C ) Trisodium phosphate D ) Caustic soda E ) Hydrazine - ✅ B An inhibitor , when added to acid will A ) Make the acid compatible with the sewer system for disposal B ) Cause foaming in the boiler C ) Strengthen the acid thereby shortening the cleaning procedure D ) Prevent the acid from attacking E ) Minimise the effect the acid has on the metal - ✅ E A boiler has been in operation for one year and is now taken off the line for cleaning , repair and inspection. The boiler is one of three in a battery and the other two will remain in operation. This one boiler is to be drained and cooled. Before any person is allowed enter the boiler drum , the correct safety procedure requires that the : A ) Main steam , blow down , blow off , and feedwater valves be closed , chained and tagged OB Person is equipped with the correct kind of tools and a list of required repairs ) Worker is provided with a safety kit for confined space entry D ) Worker is provided with a safety line , first aid kit , and hard hat E ) Drum be vented , the safety valve gagged , and all ashes and soot removed from the fire box - ✅ A The most popular acid for boiler cleaning is : A ) Sulphuric B ) Chelate C ) Hydrochloric D ) Phosphoric E ) Nitric - ✅ C When cooling down a steam boiler that has been taken out of service , a vent valve on the steam drum should be opened to prevent a vacuum at : A ) 0 Kpa B ) 100 kPa C ) 90 degrees D ) 50 % load E ) 175 kPar - ✅ E
