Body of Knowledge For

State of Ohio
High Pressure Engineers License Exam

Licensed High Pressure Boiler Operators must have knowledge on a variety of subjects
relating to power plant systems including; steam boilers, environmental controls, water
treatments, economic devices, and safe operation to prevent injury or damage. This
includes high pressure and low pressure boilers.

The State of Ohio High Pressure Engineers License Examination is designed to

determine if individuals have such knowledge. The body of knowledge is a study guide
that provides a list of specific topics in which the Boiler Operator should be
knowledgeable.

Only information covered in the categories outlined in this Body of Knowledge will be
utilized for the examination questions. Each specific examination may not cover every
topic of the Body of Knowledge.

Steam Plant Operation, 8th Edition by Woodruff and Lammers (Excluding Chapters 9 &
10) is the primary reference document. Low Pressure Boilers second edition by
Frederick M. Steingress (Excluding Chapters 9 & 10) is the reference used for low
pressure boilers

Books or other reference materials are not to be brought to the examination site, however
non-programmable calculators may be used.

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 Body of Knowledge For
State of Ohio
High Pressure Boiler Operators License Exam

Part 1 Boilers - steam cycle, fuel / energy source, utility boilers , industrial boilers,
cogeneration.

Part 2 Boiler Design / Application, heat transfer, steam properties, control devices,
furnace design, economic devices, firing equipment, and draft.

Part 3 Boilers - Construction; materials, support, types of stress, openings and fittings,
heating surface and capacity.

Part 4 Combustion – fuels, control of the rate of combustion.

Part 5 Combustion Equipment - specific types of equipment for each type of fuel
including safety devices, monitoring and adjusting fuel burning equipment, and
mechanical and draft.

Part 6 Boiler Indicators and Devices - to provide for operation, prevent over-pressure,
determine water level, valves, piping, blow down systems, and measuring
devices.

Part 7 Boiler Operation - abnormal operations, start up, shut down, efficiency, water
supplies, idle boilers, maintenance, repairing, and evaluation of a boilers’
condition

Part 8 Pumps – type, applications, facts used in selecting, conditions for operating, and
maintenance.

Part 9 Boiler Auxiliary Support Equipment – types and operation of feed water heaters,
water system make up, condensate, polished systems, blow down systems, steam
traps, separators, lubricator types and devices with their auxiliaries.

Part 10 Environment Control – types, technology, particulate control, equipment for

specific controls, mechanical, bag filter, and precipator.

Part 11 Math formulas

Part 12 Ohio Laws and Rules

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Body of Knowledge for State of Ohio High Pressure Boiler Operator License Exam

1 - Boilers
Knowledge in the operation, maintenance, repair, economics of basic systems
including the use of steam, the energy source to produce the steam, the distinction
between industrial and utility boilers, and a good concept of how steam is
generated from a heat source other than combustion within a boiler.

1.1 Steam Cycle

The Boiler Operator should know the Rankine Cycle, the effects of reheat
cycles and regenerative feed water heating

1.2 Fuel / Energy Source

The Boiler Operator should know the types of fossil fuels used in a boiler,
coal, oil, gas as well as the heat derived from nuclear fuel such as
uranium.

1.3 Utility Boilers

The Boiler Operator should know that utility boilers are those plants that
generally supply electricity to most of the United States. These boilers are
most often fired with coal but are also fired with fuel oil and gas. Utility
boilers have reheat cycles, and require very elaborate water treatment
systems.

1.4 Industrial Boilers

The Boiler Operator should know industrial boilers are most often used for
process steam, such as heating, driving operating turbines, for fans or
pumps, and other process work.

1.5 Cogeneration.
The Boiler Operator should know that cogeneration is a system in which
fuel is used to produce energy and the heat from the fuel is then directed to
be used by a boiler to conserve energy and achieve the maximum
efficiency from the heat generated.

2. Boiler Design/Application
The boiler operator should know: how the application affects the design, size, and
type of boiler to be used. Also, the types of heat transfer, how they differ, and
where each takes place within the furnace. The boiler operator must have an
understanding of the relationship between steam pressure and temperature and
how to control their parameters. The boiler operator must have knowledge of the

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Body of Knowledge for State of Ohio High Pressure Boiler Operator License Exam

rules for construction of boilers, including material properties, accessories

supplied, and heat source. Knowledge is needed for plants that span the last fifty
years or more.

2.1 Boiler Design / Application

The boiler operator should know fire tube, vertical (submerged and non-
submerged), horizontal, water tube, and cast iron type boiler construction.
The boiler operator should be able to describe the differences between
package and site-erected boilers. The boiler operator must know the
difference between a longitudinal weld joint and a circumferential weld
joint. The operator should be able to describe the flow of gases through
each type of boiler.

2.2 Heat Transfer

The boiler operator must understand conduction, convection, and radiation
heat transfer. The boiler operator should be able to describe the various
types of fluid flow and how they affect heat transfer. The density of steam
versus boiler pressure, and the meaning of saturation temperature must be
understood.

2.3 Steam, properties and Control Devices

The boiler operator should know location and purpose of a dry pipe,
cyclone steam separators, steam scrubber, or baffles. The boiler operator
should know the function, types, location, operation, start up, and
efficiency of superheaters. Have an understanding of the affects of
carryover and how it is prevented, steam quality, and desuperheaters or
attemperators.

2.4 Furnace Design

The boiler operator should understand the reason(s) for having ash re-
injection, furnace baffles, and water walls (water cooled furnace). The
boiler operator should have knowledge of soot blower operation, types
and location. Refractory walls, slag, erosion and spalling, purpose of a
water screen, flame impingement, clinkers, clinker crinders are topics with
which the boiler operator should be familiar.

2.5 Economic Devices

The boiler operator should know the construction location, types, and
purpose of an economizer, air-preheaters, and thermocouples.

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Body of Knowledge for State of Ohio High Pressure Boiler Operator License Exam

2.6 Firing Equipment

The boiler operator should understand and be able to operate pulverized
firing, chain grate firing, spreader stoker firing, and underfeed stoker
firing.

2.7 Draft
The boiler operator should understand balanced draft units, pressurized
draft unit, primary air, secondary air, tertiary air.

3. Boilers Construction
The boiler operator must be aware of the materials, design, and limits of those
materials used in the equipment in their charge. Stress the access for cleaning,
inspection, and repairs, as well as the appliances attached to the boiler to ensure it
does not exceed the limits of its design. Also the operator must know the abilities
and limits of the unit being operated to prevent failures of equipment that may
result in injury or death.

3.1 Materials
The boiler operator must have knowledge and understand limitations of
materials used in boiler construction. The boiler operator should have
knowledge of proper operating procedure which will help to prevent creep
or graphitization. Being able to specify the nondestructive examination
method to be used to inspect the boiler is also part of the knowledge
needed by the boiler operator.

3.2 Openings and Fittings

The boiler operator should know the requirement for the minimum size of
a manhole or hand hole opening. In addition, he must be able to list the
purpose of other openings in the drum, and be able to identify the process
of rolling tubes into a boiler.

3.3 Heating Surface and Capacity

The boiler operator should know the definition of heating surface, and
how twelve square feet of heating surface is related to Ohio law
concerning licensed operators and engineers. The operator must also be
able to convert evaporation rate to horsepower.

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Body of Knowledge for State of Ohio High Pressure Boiler Operator License Exam

4. Combustion
The boiler operator must be proficient in the techniques used to control fuel and
air to a furnace, thus regulating the release of heat to the boiler.

4.1 Fuels and their equipment

The boiler operator should know the combustion process, temperature
required for combustion, atomization, and absolute pressure.

4.2 Control of the rate of Combustion

The boiler operator should know how to control the supply air (oxygen)
part of combustion, the condition or degree under which combustion takes
place, flue gas analysis methods, the amount of air required to burn a
pound of fuel, and tempering of fuel.

5. Combustion Equipment
The boiler operator must be familiar with the devices used to supply fuel to the
furnace. This includes using solid, gaseous, or liquid fuels; the protective
devices, types of controls used, and understand the type or types of draft required
for each fuel including units that operate on multiple fuels.

5.1 Combustion Equipment

The boiler operator should know operation and maintenance of coal
stokers, such as chain grate, spreader underfeed, and pulverize. Must
know oil fired burners, mechanical or pressure type, and the advantages
and disadvantages of each. Also, operation and maintenance of gas fired
burners whether the supply is natural or man made. The operator must be
able to describe the method of disposing of ash and products of
combustion, and know the physical requirements of the fuel system.

5.2 Safety Devices

The boiler operator must be able to explain how to properly fire a boiler.
The boiler operator must be able to explain the importance of purging the
furnace and of heating or pressurizing the fuel. The operator must know
what devices are to be installed in the fuel system to protect it.

5.3 Monitoring the furnace

The boiler operator must be able to explain what can happen if the burner
flame is not controlled properly.

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Body of Knowledge for State of Ohio High Pressure Boiler Operator License Exam

5.4 Draft
The boiler operator shall see to it that induced, over fire, and forced draft
fans are operational, and must determine if a balanced draft on positive
pressure furnace is distributing heat and gases as required to prevent
failure in the furnace.

6. Boiler Indicators and Devices

The boiler operator must have knowledge of operation and maintenance relating
to the devices that are provided to assist in determining and maintaining water
level, steam pressure, isolating the boiler, and preventing over pressure of the
boiler. The devices shall be in the proper location, using recommended code
installation practices.

6.1 Safety Devices

The boiler operator shall know the operation, maintenance, location,
purpose, and proper installation of a boiler water column, safety valve,
blow down valve, heater/non return valve, steam gauge, fusible plug, and
feed water regulator.

6.2 Safety Valve

The boiler operator shall be able to properly test the safety valve of the
boiler and know the minimum number of valves required for installation.
The boiler operator must know the requirements for; discharge piping,
minimum blowback values, and the minimum capacity for safety valves.

6.3 Boiler Water Level Devices

The boiler operator will know the proper procedure to determine the water
level of the boiler, the location of the water column and the minimum size,
strength, and type of pipe and fittings used.

6.4 Valves and Their Applications

For each appliance, the boiler operator will know the type of valve used in
which order it is used on feed water, blow down, steam header, water
column, and all other connections to the boiler.

6.5 Instrumentation
The boiler operator shall know how to use all measuring devices, insure
that they are attached properly, and be able to perform test to prove their
accuracy. These items may include; steam gauges, draft gauges, water
gauges, fuel, and temperature gauges.

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Body of Knowledge for State of Ohio High Pressure Boiler Operator License Exam

7 Operation and Maintenance

The boiler operator must show evidence that indicates the comprehension of the
theory of the production of steam from boilers, during all phases of operation,
maintenance, repairs, and inspection.

7.1 Start Up and On-line Operation of Boilers

The boiler operator should understand the sequence of operation that leads
up to on-line operation. This includes any special considerations for new,
or newly repaired boilers.

7.2 Combustion
The boiler operator should be able to monitor, analyze, and regulate the
combustion process to operate in the most efficient and safe manner.

7.3 Operational Problems

The boiler operator needs to be able to recognize problem areas
immediately and control potentially un-safe operation. Abnormal
operation, priming and carry over, tube failure, fires, inconsistent draft,
and gauge glass breakage are some of the situations that an operator must,
at all times, be ready to handle.

7.4 Idle Boilers

The boiler operator should be able to care for idle boilers, know how to
take a boiler out of service, and know how to place a boiler in wet or dry
lay up.

7.5 Boiler Maintenance

The boiler operator should be able to; perform routine maintenance,
schedule maintenance, prepare boilers for internal inspections, and
external inspections, or repairs. To obtain maximum efficiency in
operation the boiler needs to be maintained on a regular schedule.

8. Pumps
The boiler operator shall demonstrate knowledge indicating comprehension of the
operation, maintenance, start-up and shut down of all types of pumps used
throughout a powerhouse.

8.1 Pumps
The boiler operator must be able to identify the types of pumps and the
varied uses of pumps. The operator must understand their capabilities and

Body of Knowledge for State of Ohio High Pressure Boiler Operator License Exam

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 what can be expected of injectors, duplex pumps, power pumps, vacuum
pumps, rotary pumps, and centrifugal pumps.

8.2 Pump Operation

The boiler operator needs to be able to properly line up and bring pumps
on line, regulate pump discharge and understand the performance
characteristics of the pump.

8.3 Pump Maintenance

The boiler operator needs to know when and how to care for each type of
pump, must identify the required routine maintenance, and schedule
maintenance, to maintain peak performance of all types of pumps.

9. Boiler Auxiliary Support Equipment

The boiler operator shall demonstrate knowledge that indicates comprehension of
the operation, maintenance, start-up and shut down of boiler auxiliary equipment
used through out a powerhouse. These items include pre-heating, water treatment,
distribution of steam, return of condensate, and lubrication operations.

9.1 Feedwater Heating Equipment

The boiler operator needs to know feed water heaters, closed and open,
and deaerators. The boiler operator must have a thorough understanding
of pre-heating of feedwater, and which components provide these benefits.

9.2 Boiler Water Treatment

The boiler operator needs to know water treatment. To maintain peak
performance and limit down time, water quality is of great importance to
safe operation. The boiler operator must be able to analyze and
chemically treat water for each condition. The boiler operator must
understand the affects of blowing down a boiler.

9.3 Piping Systems for Steam and Condensate

The boiler operator needs to know piping systems design, material
selection, flanges and fittings are topics with which the operator must be
familiar.

9.4 Steam Traps

The boiler operator needs to know the various designs and types of steam
traps, separators, and strainers. To gain the most efficiency from the
steam, it is dried for use using separators.

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 9.5 Lubrication
The boiler operator must understand classification and uses of lubricants
and lubricating devices. The applicant must know what provides the best
protection and reduces friction, and the different methods of application.

10. Environmental Control

The boiler operator shall demonstrate knowledge that indicates
comprehension of the operation, maintenance, start-up and shut down of
environmental equipment and to comply with environmental
responsibilities of the plants operation.

10.1 Pollution Controls and Standards

The boiler operator needs to know the types of emissions, how they are
monitored, and the operator must be able to differentiate one condition
from another, and control the situation accordingly.

10.2 Pollution Control Devices

The boiler operator needs to know how particulates are controlled,
mechanical collectors, electrostatic precipitators, bag filter houses, how to
control pollution by-products or stack gas emissions are topics with which
the operator must be familiar.. The applicant needs to identify the
different methods available and the principles of operation.

10.3 Flue Gas Scrubbers

The boiler operators needs to know how to operate sulfur dioxide
scrubber, wet scrubber, and dry scrubber. In addition to particulate
control, the chemical balance as a result of combustion needs to be
reduced to acceptable atmospheric standards.

11. Math Formulas

Math from the text the Boiler Operator must know the formulas as there will be
no books, notes, and no programmable calculators allowed.

11.1 The internal design pressure of an existing boiler.

11.2 Absolute pressure.

11.3 Rate at which tons of coal are being consumed in a chain grate stoker.

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 11.4 Pressure due to head of water.

11.5 Concentration of chlorides in boiler water.

11.6 Tons of coal to develop pounds of steam per hour.

11.7 Collection efficiency of an electrostatic precipitator.

11.8 Pounds of water to condense one pound of steam

12. Ohio Laws and rules pertaining to the licensing of Stationary Boiler Operators,
Boiler Operators, and Low Pressure Boiler Operators

12.1 Horsepower by heating surface

12.2 Licenses renewals

12.3 License revocation and expiration

12.4 Experience and schooling

12.5 Display of license

12.6 Requirements of boilers over thirty (30) horsepower by heating surface

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