2nd Class Engineer

Requirements

• Minimum age 20
• Education: High School Diploma / GED or Equivalent
• Experience: Three years Examination: Written (Oral or Practical when necessary)
• Minimum time in previous grade: One year
• Maximum Prime Mover Hp: (Unsupervised) 2500 Hp
• Maximum Boiler Hp: (Unsupervised) 600 Bhp HP Unlimited LP
• Maximum Refrigeration or Air Conditioning: (Unsupervised) - 1000 tons

Note: Boiler ratings in Pounds per Hour (more common for large boilers may be calculated by multiplying Rated Boiler Horsepower by 345

Testing Fundamentals

1. Types of boilers: Construction details, how installed in setting, purpose of each and where used to best advantage. Super heaters, air preheaters, economizers, dry pipes, internal baffles, fusible plugs (type and where installed). Types of internal feed pipes, steam and safety valve outlets, caulking tools, tube cutters, expanders and beading tools.
2. Stays: Where used, purpose, types, description, care, advantages and disadvantages of types.
3. Boiler Joints: Types, riveting and welding procedures - where used, relative strength of each type and various locations. What could go wrong, remedies. Testing tightness of rivets. Meaning of single and double sheer.
4. Boiler and furnace: Washing of shell and tubes, cleaning and inspection, how often, purpose, valves fittings and settings, description of methods and parts checked. Tube, shell scrapers, and brushes, air and water tubing tools.
5. Corrosion, pitting, grooving, fire cracks, bulging, bagging, blistering: Causes, dangers, prevention and remedies.
6. Water glass and column: Maintenance, what could go wrong with either, importance as a safety factor in operating.
7. Steam gauge and siphon: Principle of operating, where placed, cares, failure, how and when tested, importance as a safety factor in operating.
8. Safety valve, relief valves, and rupture discs: Purpose, care, how and when tested, description, potential failures, adjustment for blow down, reason for chatter, how drains and outlet piping installed.
9. Elementary combustion: Difference in heating value between anthracite and bituminous coal, oil, gas and coke. Cause and prevention of smoke, purpose of stack damper, methods of firing. Purpose of baffles, bridge walls, and combustion chamber. Cause of clinkers, how reduced and how removed. Maintenance and repair.
10. Soot: Effect, prevention and removal, operation of soot blowers, loss of efficiency due to soot.
11. Draft: What is it? How created? Purpose, types, controls, measurement, factors affecting draft, purpose of chimney, amount of draft created by chimney per 100 feet of height.
12. Operation of an oil or gas burner and electric boilers: Starting, stopping, controls, safety devices, types of oils in oil burning installations and how used, types of burners, dangers connected with oil burning installations, care of automatic equipment and knowledge of what could go wrong.
13. Operation of stokers: Types, how started, how controlled, advantages, maintenance, how ashes are removed.
14. Feed water piping and valves: Location, care, typical installations.
15. Description of simplex, duplex, rotary, centrifugal and vacuum pumps: Starting a feed pump, knowledge of proper operation, setting valves in steam pumps, lubrication, packing used and how to apply on all applications connected with steam feed pumps.
16. Injector: Principle, purpose, construction, care and maintenance, how connected, malfunctions.
17. Air compressor systems: How to start, how to operate, details of cooling system and how controlled, details of lubrication, danger in operating air compressors, controls, filters and safety devices.
18. Refrigeration: Starting, operating, cycle, purpose of safety head, charging, expansion, suction, discharge, cross over, purge, liquid and oil valves. Purpose of condenser, receiver, compressor, oil separator and evaporator, types of condensers. How ammonia is added and removed; how air is removed. How to defrost. Effect of excess oil, how to add oil, type of oil, type of packing, how to pack stuffing boxes, purpose of brine pumps.
19. Steam plant accessories: Back pressure valves, nonreturn valves, throttle valves, expansion joints, feed water regulators, steam separators, sight feed lubricators, steam traps, reducing valves, sprinkler systems - function, location, operation, care.
20. Steam condensers: General knowledge of condensers, where, how, and why they are used, general care and upkeep of condenser auxiliaries.
21. Feed water heaters: Types, purposes, locations, advantages, disadvantages, maintenance. Potential failures.
22. External engines: Types, setting valves, purpose fly wheel, eccentric, governor, cross head, lead, lap, angle of advance, valve travel and cut off, methods of lubrication and application to various parts, how started and how shut down, maintenance and care, dangers.
23. Steam turbines: General knowledge of the lubricating system, governors, and throttle valves.
24. Internal Combustion: Types, what they are used for 2 stroke, 4 stroke, fuels/compression ratio, construction, solid fuel systems, lubrication principles, air intake systems, exhaust systems, injector systems.
25. Electrical equipment: Definitions of switches, rheostats, circuit breakers, disconnects, rotors, stators, armatures, commutators, slip rings, two and three pole switches, volts, amperes, watts, Ohms, lamps in series, lamps in parallel. How current flows. Definitions of magnetism, induction, frequency, meaning of a short circuit and how it is caused. Meaning of a ground wire. How is electric current measured. Explanation of how two wires are formed into a joint. Calculations for computing sizes of fuses in lighting and motor circuits. Dangers connected with the operation of a motor or generator.
26. Operation and maintenance of controls.
27. Air pollution and ecology.
28. Heating, air conditioning and ventilation: Methods, controls, meaning of water hammer, piping arrangements, radiation, vacuum and plenum systems in mechanical ventilation, gravity and vacuum steam systems, maintenance.
29. Scale: What is it? How does it get into boiler? Dangers of too much, how prevented and how removed, where is it found?
30. Feed water treatment: Methods, how applied and controlled. Knowledge of impurities in feed water and their affect on a boiler under pressure and temperature. How to reduce these affects. Priming and foaming, meaning, causes and remedies. Purpose of continuous blow down and when used. Purpose of main blow down and when used.
31. Mathematics: Sufficient knowledge to enable candidate to work problems involving multiplication, division, decimals, measurement, square roots of numbers, powers of numbers, reciprocals, ratio and proportion, and formulas.
32. Gas Turbines/ Combined Cycles: Thermodynamic principles, heat energy, power laws, Combustion theory. Gas Turbine theory, Brayton Cycle, Rankine Cycle, Simple Cycle Gas Turbine . 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. Plant Safety.