1st Class Engineer

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1st Class Engineer
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Requirements

  • Minimum age: Adult
  • Education: High School Diploma / / GED or Equivalent
  • Experience: Four years Examination: Written (Oral or Practical when necessary)
  • Maximum Prime Mover Hp (Unsupervised): 7500 Hp
  • Maximum Boiler Hp (Unsupervised): 1500 Bhp HP - Unlimited LP
  • Maximum Refrigeration or Air Conditioning (Unsupervised): 5000 tons

Testing Fundamentals

  1. Steam boilers and generators: Types of boilers, principles, advantages and is advantages. Steam, electric cylindrical, vertical, locomotive, water tube, fire tube, packaged boilers, flash boilers and Scotch marine boilers. Steam accumulators. Externally fired, internal fired boilers. Heating surfaces, how computed, types relative to horsepower rating. Super heaters, pre- heaters, economizers, dry pipes, internal baffles. Where and how installed and purpose of each.
  2. Boiler construction: Various forms, plates, rivets and welding used. Meaning of shearing stress, tensile stress, modules of elasticity, bursting pressure, working pressure, factor of safety, tensile strength. Meaning of pitch percentage of plate strength, percentage of rivet strength, unit section of plate. How to calculate strength of boiler heads, shells, efficiency of joints, stays. Description and sketches of joints. Relative strengths of various joints and how computed. How to calculate combined efficiency of riveted joints. Computation of working pressure given, tensile, strength, factor of safety, thickness, radius of shell, and efficiency of a joint. Calculations for the tube ligaments and dished heads. Staying of flat surfaces, types of stays, limitation of stress and allowances for various types of stays. Constants for different forms and applications of stays, doubling plates. How to calculate the area of the heads or segments of boilers.
  3. Boiler settings: Types, purpose, description, radiation. Bridge walls, baffles, ignition, mixing and deflection arches, combustion chambers, furnaces. Meaning of refractory lining, combustion space, Dutch ovens. Importance of sufficient height over grates. Affect of combustion space on capacity and efficiency. How to build or repair bridge walls and setting. Sketches of typical settings. Materials and cements used.
  4. Inspection and testing: Washing of shell and tubes, cleaning and inspection, how often, purpose. Valves, fittings and settings. Description of method and parts checked, what to look for, possible defects and how corrected. Hydrostatic tests and how applied. Purpose and value.
  5. Fuels: Classification of wood, coals, gas, oil and waste heat. Coal sampling and analysis, comparative heat values of various coals and other fuels, applications of various fuels, storage of coal. Knowledge of the methods used in handling coal and ashes, losses in handling. Cause, prevention and removal of clinkers.
  6. Combustion: The combustion process and reactions. Theory and practice. Air requirements, supply and control. Draft measurement and controls. Description and sketches of various draft gauges. Dampers, purpose and controls. Amount of draft needed under and over fires. Balanced draft and its practical meaning. Description of flue gas analyzer, how and where used. Combustion efficiency and how obtained. Temperatures in the furnace and breeching. Excess air and its effect on efficiency. Advantages of forced and induced draft. Air pollution. Transfer of heat to boiler water. How heat is transferred.
  7. Oil and gas burner installations: Types of burners, types of oils used in oil burning installations and how used. Dangers connected with burning installations. How to operate and maintain automatic equipment. Make sketch of one type each of industrial burner for gas and oil. A sketch of piping, valves and allied equipment for an oil fired package boiler.
  8. Mechanical stokers: Types, principles, purpose, description, comparison. How operated, how maintained and repaired. Controls, what could go wrong, remedies.
  9. Piping: Computation of sizes for water and steam, how installed, allowance for drainage and friction, flow of steam, Napiers rule, sizes of piping for pump discharge, and the feed line to boiler.
  10. Pumps - General knowledge of a simplex, triplex, weir, rotary centrifugal and duplex or vacuum pump: Knowledge of proper operation. Where installed. Lubrication. Types of water pistons. Performance. Packing uses and how applied. What could go wrong, how to calculate size of pump for a feed line to boiler rating and over rating.
  11. Air compressor systems: How to start, how to operate. Details of lubrication. Purpose of unloaders, description and sketches. Compound compressors, intercoolers, after coolers, air receivers, controls, filters and safety devices. Inspection. Dangers in operating air compressors .
  12. Refrigeration: Cycle theory of how heat is abstracted. Common refrigerants and their properties. Direct and indirect systems. Purpose, location and sketches of safety head, condenser, receiver, compressor, oil separator and evaporator. Types of condensers. How to operate refrigeration systems. How to charge, reduce or remove refrigerant from system. Changing or adding oil. Pumping out, condensing and defrosting, dangers in operating. Annual inspection. Why cooling water on compressor and condenser. How ice is manufactured. How ammonia leak is found and stopped. Refrigeration capacity and losses. How air is removed. Types of oil, how added, effect of too much. Types of packing, how applied. Purpose of brine pump. Controls, absorption systems, hand and automatic. Safety valves and discharge pipes.
  13. Steam plant auxiliaries: Super heaters, economizers, air preheaters, feed water regulators, feed water heaters, temperature regulating valves. Flow meters return thermostatic and bucket traps. Back pressure valves, nonreturn valves, safety valves, reducing valves, boiler feed pump governors, air unloaders, expansion joints, steam separators, oil burners, calorimeters, ejectors, siphon, sight feed lubricators. Descriptions and sketches of each.
  14. Feed water heaters: Types, sketches, saving fuel, Deareator, trays, filters, oil separators, back pressure valves. Position of various types, water measurements. Temperatures and pressures carried, water seals. Possible malfunctions.
  15. Steam condensers: General knowledge of the construction of the different types of condensers, together with a knowledge of their auxiliaries and advantages gained by the use of condensers on various types of engines and turbines.
  16. External engines: General knowledge of types - simple, compound, triple expansion, quadruple, uniflow, Corliss, high speed, slide valve. Specific knowledge of one type of engine. Governors, throttle, inertia, centrifugal, shaft. Sketches of governors. Types of valves. How to set valves on various types of engines. Methods of lubrication and application to various parts. How to start and how to shut down. Maintenance, care, and dangers. How to read indicators and indicator diagrams.
  17. Steam turbines: General knowledge of how turbines convert heat energy into mechanical energy and able to describe the bearing, oiling system, governors, and auxiliaries used with turbines. Specific knowledge of dangers relative to starting and stopping a steam turbine.
  18. Electricity: Meaning of terms - cycle, phase, starting torque voltage drop and voltage fluctuation, excitation, motor clearance, electrical horse power, auto transformer, starter taps, disconnect, inductance, collector rings, slip, commutator, switch board, ground wires, power factor, peak load, magnetizing current, circuit breaker, no voltage release, overload relay, transformer, bus bars, dynamometer, frequency reactance, resistor, synchronism, brush rocker, EMF impedance, interpole, lag, motor converter, rheostat. Description of main types of AC motors, characteristics and applications. How these various types are started and controlled. Connection or wiring diagrams for each type. Description of auto transformer, starter, also of magnetic contractor starter, and of a triplex rheostat. Care and maintenance of electrical machinery and equipment. Troubles, testing, and correction.
  19. Heating, air conditioning and ventilation: Methods, controls, piping installations. Radiation, vacuum and plenum system in mechanical ventilation. Gravity and vacuum steam systems. Design, operation and maintenance.
  20. Feed water conditioning: General knowledge of the chemical changes that occur when feed water is heated in a boiler. Scale, what it is and what causes it, danger of too much. Impurities generally found in raw waters. Carry over, embrittlement, corrosion. Methods of conditioning, internal and external treatment. Hot and cold lime soda, Zeolite, demineralization, ion and anion exchanges, supplementary phosphate treatment. Caustic soda and its application. Water analysis, tests, parts per million, grains per gallon, soap hardness test. Alkalinity test (PM and PH), chloride, sulfite use of chelants, and phosphate tests, total dissolved solids.

  21. Mathematics: Knowledge of fractions, decimals, percentage and square root. Knowledge of how to find the area and circumference of a circle, also the volume of a cylinder. Understanding of the relationship between the sides of right angle triangles. Knowledge of the method of solving problems relating to a chain of gears, pulley sizes, rope blocks, screw jacks, levers, etc. Understanding of the factor of evaporation, equivalent evaporation, latent heat, total heat, and a definite understanding of the problem involving the abstraction or supply of heat, relation to heating water or making ice. How to solve problems in heat supplied and extracted. How to compare boiler performances. How to solve problems involving heat calculations of steam production, boiler efficiency and horse power. How to find the horsepower of an engine from an indicator diagram. How to solve problems in heat supplied and heat extracted and how to compare boiler performances. How to solve problems involving heat calculations of steam production, boiler efficiency horse power. How to find the horsepower of an engine from an indicator diagram. How to solve problems involving specific gravity, calculations involving steam pressure on areas, how stays are calculated and deigned. How to solve problems involving cost of operation relative to fuel and labor costs. How to calculate heating surface and horsepower of various types of boilers.

  22. Chemistry and physics: Basic fundamentals as applied to power plant theory and practice.

  23. Lubricating oils: Knowledge of the ingredients and qualities of oils. How they are filtered and applied. Storage of oils.

  24. Types of steam power plants: Simple, non-condensing, elementary condensing, turbo-alternator plants, central stations, high-pressure plants, super pressure plants (power). Distribution and losses in each type.

  25. General Knowledge: British thermal unit, foot pound, latent heat, specific gravity, specific heat, mechanical equivalent, inertia, convection, matter, momentum, siphon, clearance pockets, intercooler, after cooler, horse power of boiler, horse power of engine, ton of refrigeration, axial flow, dynamic static, alkaline, freon, propane, atomic weight, barometer, hydrometer, Boyles Law, capillary, caustic soda, oscillation, center of gravity, centrifugal force, cohesion. Velocity Speed Acceleration Conversion (°F-°C-°R), mean effective pressure, density, back pressure, oxidation, thermal efficiency.

  26. 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. 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. 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.