Chief Engineer

Requirements

• Minimum age: Adult
• Education: High School Diploma (Oral or Practical when necessary)
• Experience: Five years Examination: Written (Oral or Practical when necessary)
• Minimum time in previous grade: One year
• Maximum Prime Mover Hp: Unlimited
• Maximum Boiler Hp: Unlimited
• Maximum Refrigeration or Air Conditioning (Unsupervised): Unlimited

Testing Fundamentals

1. Steam boilers and generators: Types of boilers - waste heat, incinerators, cylindrical, vertical, horizontal, locomotive, fire tube (straight and bent tube), packaged boilers, flash boilers, Scotch Marine boilers, reheat and integral furnace boilers. Steam generators (modern central stations), monotone, forced circulation, radiant, mercury boilers - description and sketches.
2. Boiler construction: Various forms, plates, rivets, stays, braces, joints, factors, welding, etc. (used under ASME Code). Meaning of shearing, tensile stress, modules of elasticity, bursting pressure, working pressure, factor of safety, tensile strength. Meaning of pitch, percentage of plate and rivet strengths, unit, section of plate. How to calculate the strength of boiler heads, shells, stays, efficiency of joints. Description and sketches of joints. Relative strengths of various joints and how calculated. How to calculate combined efficiency of riveted joints. Computation of working pressure, given tensile strength, factor of safety, thickness and radius of shell, plus efficiency of joint. How to stay flat surfaces, including types of stays, allowances for limitation of stresses, and constants for various types of stays and doubling plates. How to calculate the area of the heads of segments of boilers, etc.
3. Boiler settings: Types, purpose, descriptions and sketches. Radiation and bridge walls, ignition, mixing and deflection arches, baffles. Combustion chambers and furnaces. Meaning of refractory lining, combustion space, dutch ovens, extension front. Importance of sufficient heights over grates. Effect of combustion space on the capacity and efficiency. How to build or repair bridge walls and setting, materials and cements used in settings. Cyclone primary furnaces, solid refractory, air-cooled or water cooled walls, water screens, slag tap, dry bottom, and hopper bottom furnaces.
4. Inspection and testing: Washing of shell and tubes, cleaning and inspection procedures relative to shell, how often and purpose. Cleaning and inspection of setting, auxiliaries, valves and fittings, description of methods used and parts checked. How to inspect, what to look for, possible defects and how corrected. Hydrostatic tests and how applied.
5. Fuels: Classification of wood, coal, gas, oil and waste heat. Composition of coal, coal sampling and analysis, proximate and ultimate analysis, Dulongs formula. Comparative heat values of various coals and other fuels. Storage of coal and other fuels. Losses in handling. Advantages and disadvantages of each type of fuel.
6. Combustion: Fundamentals of the chemistry of combustion, stages of combustion, the combustion process and reactions. Combustible constituents of various fuels, the incombustible for complete combustion. Theoretical and actual weight of air required per pound for combustibles. Flue gases and analysis, the flue gas analyzer apparatus, automatic flue gas recorder. Combustion efficiency and how obtained, excess air and its effect on efficiency. Value of CO2, CO and O2 readings. Air requirements, supply and control. Temperatures, measurement and controls in furnace, passes and breeching. Smoke, cause, measurement and prevention, smoke density recorder, Ringlemann chart. Losses due to flue gas, combustible in ash, moisture in fuel, moisture from combustion of hydrogen, moisture in air and radiation plus heat absorbed by boiler or a complete heat balance.
7. Draft: Natural, chimneys, stacks, types and determination of size. Empirical chimney formulas, mechanical draft, induced and forced draft. Prat, Evase or Thermix systems. Balanced draft systems and controls, measurement of draft, descriptions and sketches of various draft gauges. Amount of draft needed under and over fire (in passes and stack in various settings and types of fuel and the methods of burning the fuel). Fans - types and controls. Breechings and dampers. Systems - description and sketches.
8. Oil and gas burner installations: Types of burners, types of oils used in oil burning installations, heat values, how and where used. Methods of burning fuel oil, methods of burning gaseous fuels. Dangers connected with oil and gas burning installations. Description of controls. How to operate and maintain automatic equipment. Sketches of industrial burners for gas and oil, sketches of oil burning plant layouts.
9. Mechanical stokers: Types, overfeed, underfeed, chain grate, vibrating grate, spreader or sprinkler. Principles, purpose, description, comparison, sketches. How operated, maintained and repaired. Controls, what could go wrong and how to remedy. Feed and driving mechanisms.
10. Pulverized coal systems: Types, storage or central, direct or unit. Horizontal and vertical dryers. Applications, sketches of pulverized systems. Vertical, horizontal, Tangential, cyclone, inter-lube burners and feeders. Vertical and horizontal pulverizes and dryers.
11. Coal handling and ash handling equipment: Manual, conveyors, scraper flight, bucket, belt apron, grab bucket, telepherage systems. Coal crushers and breakers, hoppers, and coal valves. Storage internal and external - by pile, silo or bunker. Coal weighing lorries, hoppers and coal valves, sketches and descriptions. Ash handling - manual, gravity, hydraulic, submerged cross bar, pneumatic, skip hoist and steam jet conveyor. Simple and compound cyclone fly ash collectors, sketches and descriptions.
12. Piping: Computation of sizes for water, steam, gas and oil. How installed, allowances for drainage and friction. Flow of steam. Napiers, Briggs, Babcocks, Shitzgrass and Fritsoche's rules. Sizes of piping for pump discharge and feed line to boiler, pipefittings, expansion joints, U bends, flanges and gaskets. Piping layouts - sketches of sizes, location of piping and valves. Pipe hangers, roll anchors and brackets, and pipe coverings.
13. Pumps: General description of a simplex, duplex, triplex, weir, rotary, centrifugal or vacuum pump, specific knowledge of two types of pumps. Knowledge of proper operation and maintenance. Where and how installed, lubrication. Types of water pistons, packing used and how applied, capacities and applications. Dynamic, friction and velocity heads. What could go wrong. How to calculate size of pump for a feed line to boiler at rating or over-rating.
14. Air and gas compressor systems: General knowledge of various types of compressor efficiency, isothermal and adiabatic compression. Air compressor valves, automatic, mechanical, types, descriptions, sketches, maintenance. Speed regulation. Governors on steam or diesel engines. Constant speed. Unloaders, closed and open intake, discharge, clearance pocket, description and sketches. Intercooler, after cooler. Receivers. Cooling systems, descriptions and sketches. Lubrication, types of oil and how applied, danger of too much oil. Safety devices. Inspection and overhauls. Dangers in operation - causes of explosions. Internal combustion engines - principles, operating and maintenance. Installation and general layout of air compression systems. Gas compression - natural, illuminating, gas absorption process, vapor recovery, stabilization and refractionation. Application of compressed air, free air, standard air. Heat of compression, volumetric, compression, mechanical and overall efficiencies. Dew point and humidity.
15. Refrigeration: Cycle of compressor system, theory of how heat is abstracted, common Refrigerants and their physical properties, direct and indirect systems. Purpose, location, description and sketches of a safety head, cylinder, valves, safety valves, condensers, receiver, compressor, oil separator, evaporator. Flow equipment, such as automatic purgers, dehydrators and heat exchanges. Types, descriptions and sketches of condensers, of hand, automatic and thermostatic expansion valves, low and high side float valves. Types and descriptions of compressors, single and double acting, rotary, centrifugal and steam jet. Types and descriptions of evaporators, flooded, dry expansion, convection and forced draft. Electrical controls and control valves. Back pressure and temperature controls. Constant pressure, snap action, check water regulating, valves. High pressure and low water cut outs. Pressure relief devices. Lubrication, selection and characteristics of oils, pour point, viscosity, cloud point and moisture content. Splash feed and forced feed, adding or changing oil, effects of too much oil. Compressor drives, electric, steam, diesel or gas engine. Operating and maintenance of compressor system, starting and stopping. How to charge, reduce or remove refrigerant from system, pumping out condenser and defrosting, dangers in operation, effect of air and how controlled, purging. How ammonia leak is found and stopped. Annual inspection and overhaul. Compressor calculations, cylinder displacement, volumetric efficiency, power requirements for condenser. Brine in refrigeration. Chemistry, brine pumps, corrosion control, congealing, hold over tanks and eutectic plates, liquid cooling and ice making. Absorption systems - intermittent, continuous and Electrolux, description, application, cycle and sketch. The Refrigeration Code.
16. Steam plant auxiliaries: Super heaters, economizers, air preheaters, feed water regulators, feed water heaters, temperature regulating valves, impulse, flow meters. Return, float, thermostatic, expansion, dump, differential, siphon, and bucket traps. Back pressure, nonreturn, safety, motor operated and reducing valves, boiler feed pump, governors, air unloaders, expansion joints, steam separators, calorimeters, oil burners, ejectors, siphons, sight, forced and hydrostatic lubricators, automatic expansion valves, simple steam lock, thermostat and diaphragm valves, meters, steam accumulator, internal drum steam washers or separators - descriptions and sketches.
17. Practical knowledge of super heaters, desuperheaters, reheaters, purifiers and Attemperator: Types, locations, advantages, economy, performance, controls, and safety devices.
18. Feed water heaters: Purpose, types, open, closed and extraction. Deareator, trays, filters, oil separators, back pressure valves. Water seals and meters - location, description, sketches. Temperatures and pressure carried. Saving in fuel. Maintenance, malfunctions.
19. Economizers and air preheaters: Types, advantages and disadvantages, locations, soot removal and soot blowers. Description and sketches, heat balance diagrams.
20. Steam condensers: Fundamental principles, parallel flow, counter current, low level, barometric, low and high vacuum, siphon or ejector. Surface, water or air cooled evaporative. Air pumps, circulating, dry vacuum, centrifugal entrainment, air ejectors. Cooling ponds and towers, types of water, natural and mechanical cooling towers. Sketches and descriptions of various types of condensers and auxiliaries.
21. External engines: General knowledge of types - simple, compound, triple expansion, quadruple, uniflow, Corilss, high speed and slide valve; specific knowledge of one type. Governors, throttle, transformer, inertia, centrifugal, cutoff. Sketches and descriptions of two types. Types of valves, high speed, Corliss, wheel-lock, simple slide, balanced valves and poppet valves, sketches. How to set valves on various types of engines. Methods of lubrication and application to various parts, positive pressure and hydrostatic cylinder lubricators, centrifugal crank pin oilers and chain oiling. How engines are started and how shut down. Maintenance and care, dangers. Indicators, indicator diagrams and how to interpret the same. Indicated horse power, brake horse power, pony brake, mechanical efficiency cycle, heat balance of engine.
22. Steam turbines: Fundamental principles of operation, classification of steam turbines. General knowledge of types - Impulse, Rateau, Curtiss, De Laval, Terry, Kerr Sturtevant, Coppus Reaction, Parsons, Allis Chalmers, Westinghouse, Brown Bovery, Ljungstron, General Electric and Worthington. Compound, exhaust steam, mixed, back pressure, pass out or bleeder turbines; specific knowledge of one type. Diagrammatical sketches showing compounding by pressure and velocity in impulse and reaction turbines. Assembly of blades, nozzles and diaphragms in various forms. Dummy pistons, Kingsbury thrust bearings, etc. Turbine glands and gland sealing. Hydraulic, carbon ring and labyrinth glands. Lubrication forced and combined. Automatic regulating valves for auxiliary oil pump, description and sketch. Types and properties of oils. Sketch of forced lubrication system. Oil filters and purifiers. Governors and governing. Types, descriptions and sketches. Emergency stops and controls, descriptions and sketches. A general knowledge of installation. Preheating and drainage of turbines. Starting and stopping turbines. Inspection and overhauling. Turbine troubles and how corrected, erosion of blading stresses in turbine rotors, critical speed of turbine rotors.
23. Electricity: A practical knowledge of electromagnetism. Ohms. Coulomb, Joules, and Kirchoffs Laws. Laws of induction, self-inductance, mutual inductance. Current in revolving loop. Direct current generators. Field frame, magnetic poles and windings, armature core and windings, commutator brush rigging and brushes. Sine curve. Commutation, excitation, characteristics of series, shunt and compound generators. Operation of machines in parallel. Starting and control of D.C. generators. Direct current motors. Types, characteristics and applications. Effect of armature reaction. How to install brush rigging and brushes on D.C. motors. Starting and control of D.C. motors. Types of controls and connection diagrams. No voltage release. Overload release.
24. Alternating current generators. Alternators, types, single and polyphase, revolving armature, revolving field induction, self excited, separately excited, slow or high speed. How does AC produce a revolving magnetic field. Description of mechanical construction, rotor, stator, slip rings, bush gear, damper or amortisseur windings, exciter how started, how controlled, how stopped. Phasing out, synchronizing, operation in parallel, division of load. Starting, pull in and pull out torque's. Description of starting equipment and connection diagrams. Voltage regulation and regulators. A. C. Motors. Theory, revolving magnetic field, slip, running speed, no load and full load. Types, squirrel cage, wound rotor, single phase, synchronous motors. Converters. Construction, characteristics and applications. Multi-speed squirrel cage motors. Classification of A. C. motors, open, semi enclosed, totally enclosed, fan cooled, enclosed ventilation, vertical motors. Starting and control of A.C. motors. Types of controls and connection diagrams. No voltage released. Overload release. Switch gear, circuit breakers, relays, rheostats, switchboards, instrument transformers, bus bars, disconnects. Description and sketches. Connection diagrams for switchboards and motor converter sets. Electrical meters - ohmmeter, voltmeter, ammeter, wattmeter, watt hour meter, frequency meter, synchroscope, fundamentals and applications. Power factor - meaning, factors controlling power factor, effect on generators, motors and lines, how improved. Transformers - principles and types, core and shell types. Construction of core and coils, cooling, windings and connections. Losses and regulation. Electrical calculations and conversion factors. Horse power ratings and speeds of motors and generators, comparison with boiler and engine horse power. Ratings of circuit breakers. Computation of size of motor, generator or transformer for various applications. Service factor. Calculations needed in power factor improvement. General knowledge of electric boilers - construction, controls, operation. Lubrication, oil ring, grease closures for all and roller bearings, inverters and batteries.
25. Testing and measuring apparatus: Coal meters, fluid meters, steam flow meters and recorders, Bourdon pressure and vacuum gauges, draft gauges, recording draft and vacuum gauges, thermometers, pyrometers, flue gas analyzer apparatus, CO2 recorders, calorimeters, Bailey smoke density recorder, counters, tachometers, dynamometers, pony brake, boiler control panels - description and sketches.
26. Ecology: Ecosystems, water quality control, general criteria for all waters, water treatment, wastewater treatment, sterilization, air quality control, impurities in the air, sources of air impurities, particulate matter.
27. Heating, air conditioning. and ventilation: Fundamentals of control and measurement, electric and pneumatic control circuits, zone and unit controls, controllers, types. Actuators, types. Valves and relays. Piping, fans and duct work. Vacuum and plenum systems in mechanical ventilation. Radiation, gravity and vacuum steam systems. Designs, installation, operation and maintenance. Descriptions and sketches of HVAC systems.
28. Feed water conditioning: Scale, what it is and what causes it; dangers of an excess. Impurities generally found in raw waters; characteristics and chemical formulas. Methods of conditioning; internal and external treatment, hot and cold lime soda, Zeolite, demineralization, ion and anion exchanges and supplementary phosphate treatments. Caustic soda and its application. Water analysis, parts per million, grains per gallon, tests, soap hardness, alkalinity (PM and PH), chloride, sulfite, phosphate, total dissolved solids, use of chelants. Value of blow down (both main and continuous), how controlled and measured. Meaning of carry over, priming, foaming, embrittlement, corrosion, grooving, how prevented, sketches of one form of external treatment. 28. Rating, efficiency, and testing of steam boilers: Heat output in steam units. Units of evaporation - actual, factor of, and equivalent, evaporation. Horse power rating - ratio of heating surface to performance - (1) efficiency, (2) rate of combustion per grate surface, (3) rate of combustion per pound of fuel, (4) heat transferred per square feet of heating surface, (5) heat liberated per cubic feet of furnace volume - unit testing, comparison with standard or guaranteed results. Recording of data and results of a boiler test run.
29. Mathematics: Knowledge of how to find the area and circumference of a circle and the volume of a cylinder, pyramid and cone. Also, the volume of the frustums of pyramids and cones; how to find the area of the segment and zone of a sphere. Knowledge of algebra of simultaneous and quadratic equations and logarithms. Working knowledge of problems as covered in boiler construction and repair through the use of the A.S.M.E. Code or jurisdiction code. Understanding of the relationship between the sides of right angle triangle. Knowledge of the methods of solving problems relating to a train of gears, pulley sizes - rope blocks, screw jacks, levers, wheels, and axles, etc. Definite understanding of the meaning of the factor of evaporation, equivalent evaporation, latent heat, total heat; of problems involving the abstraction or addition of heat relative to heating water or making ice or steam. How to solve problems involving heat calculations of steam production, boiler efficiency and horsepower; also to compare boiler performances. How to find the horse power of an engine from an indicator diagram by a pony brake or a dynamometer. How to solve problems involving specific gravity and specific heat, Boyles and Charles Laws, the parallelogram of forces, Newton's Law. How to solve questions covering economy of operation relative to fuel and labor costs. How to calculate heating surface and horsepower ratings of various types of boilers.
30. Physics, mechanics and chemistry: Matter, force weight. Two or three acting at a point. Triangle, polygon and parallelogram of force. Movements, parallel forces. Couples, center of gravity. Work, mechanical advantage, velocity ratio, energy, power, efficiency. Friction, velocity, acceleration, inertia. Transmission of motion and power. Hydraulics, Machines, levers, pulleys, wheel and axle, inclined plane. Heat. Measurement. Expansion rate. Charles-Guy Lussac, Boyles Laws. Theory of siphon and barometer. Losses in power and heat transmission through modern steam plant. Joules equivalent. Chemistry. Quantitative Laws. Colloids, periodic law, structure of atom, atomic weights of elements related to combustion. A general knowledge of such metals as copper, brass, iron, magnesium, calcium, zinc, aluminum, lead, antimony, nickel, steel. The alkali metals, lithium, sodium, potassium, etc.
31. Internal Combustion: Types, what they are used for, 2 stroke, 4 stroke, fuels, gas fuels, compression ratio, construction, solid fuel systems, lubrication system, air intake systems, exhaust systems, injector systems, maintenance on and off line. Descriptions and sketches of internal combustion engine systems.
32. Gas Turbines/ Combined Cycles: Thermodynamic principles, heat energy, power laws, Combustion theory. Gas Turbine theory, Brayton Cycle, Rankine Cycle, Simple Cycle Gas Turbine . Gas Turbine construction, aero derivative, heavy duty industrial, combustion system and arrangement , annular combustion system, silo type combustion system, can annular combustion system. Gas Turbine Compressor System Gas Turbine Cooling System, Turbine Blade Cooling System. Environmental Aspects, Gaseous fuels, coal gasification, solids fuels. Bearing System, Lubrication System. Heat Recovery Steam Generators, Operating System, function, principles of operation, HRSG low pressure section, intermediate section, high pressure section and components. Duct burners, economizer, fresh air systems, HRSG auxiliary systems. . Descriptions and sketches of Combined Cycle Units.
33. Management: The human factor, methods, time and motion, work analysis, work, improvement, records, charts and diagrams, work sampling, quality control.
34. Economics: Elementary economic concepts, evolution of economic activity, economic systems, production, organization, marketing, risk transportation, consumption, supply and demand, money credit and banking, changing value of money, distribution of income, population problem, labor problems, public utilities.
35. Maintenance programs: Meaning and scope of maintenance control, developing yardsticks and benchmarks for measuring maintenance principles of control, forecasting, preventive maintenance programs, work authorization, planning, routing, material control, tool control, scheduling.
36. Supervision: Human relations, the art of supervising, controlling manpower, establishing controls, work procedures, establishing training, safety, work schedules establishing control through reports and follow-up per OSHA instructions.
37. Technical Writing: How to write a business letter, memoranda, data sheet, writing technical explanations. Report writing, gathering data, format, use of different types of reports. Reading of related subject matter.
38. Practical knowledge of various types of steam power plants: Simple non-condensing, elementary condensing, turbo alternator plants, central stations, high-pressure plants, super pressure plants. Layout, heat distribution and cycle by description and sketch.
39. Lubrication: Oils - vegetable, animal and mineral. Physical tests and applications. Lubrications, oil cups, telescopic oil ring, centrifugal, pendulum, hydrostatic, sight feed, forced feed, gravity, compressed air feed, filters and by-pass systems.
40. Working sketches, as required of general equipment in the above sections: Need not be to scale, but should be in general proportion. Details of parts could be enlarged adjacent to sketch if necessary.
41. Machine and mechanical drawing of a test piece: Showing as many views as will show all dimensions. Drawing must be to scale. Neatness and accuracy are essential. Details must be shown sufficiently that an identical piece can be made from the drawing.
42. Erection: Foundations, layout, form building, templates, lining up engines, method of bedding shaft, fitting, testing alignment, grouting, assembly, adjustment, testing, etc.
43. Real property improvement: Nature and scope, determining the value of property and equipment, inventory, depreciation, estimating endurance and use, control of repair and rehabilitation.
44. Computer Literacy: Spreadsheet, word processing, project managing, time Management.