Body of Knowledge For

State of Ohio
Low Pressure Boiler Operator Exam

Licensed Low Pressure Boiler Operators must have knowledge on a variety of subjects
relating to the operation compliance standards, boiler devices, feedwater supply
arrangement, heating sources, steam distribution, draft, boiler water treatment, boiler
operation, boiler operator safety, Ohio laws and Rules, as these pertain to the operation of
Low Pressure Boilers.

The State of Ohio Low Pressure Boiler Operator 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 about which the boiler operator should be knowledgeable.

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

Low Pressure Boilers second edition, by Frederick M. Steingress is the primary reference
document. (Excluding Chapters 9 & 10)

Books are not to be brought to the examination site, however non-programmable

calculators may be used.

Updated: 01/05/06
 Body of Knowledge For
State of Ohio
Low Pressure Boiler Operator Exam

Part I Principles and Standards

Part II Boiler Devices

Part III Feedwater Arrangement

Part IV Valves, Piping & Accessories

Part V Heating Sources

Part VI Draft

Part VII Make Up Water Treatment

Part VIII Operating Procedures

Part IX Operating Safely

Part X Laws and Codes

Updated: 01/05/06
 Body of Knowledge For
State of Ohio
Low Pressure Boiler Operator Exam

1. Principles and Standards

Low Pressure Boiler Operators will be able to define a boiler, describe the types,
functions, and uses of boilers that produce steam, under fifteen pounds per square
inch pressure. Furthermore, the operator should be able to describe the use of any
such steam, giving consideration to the safety, combustion, heat recovery,
economics, and conservation.

1.1 Low Pressure Boiler

The Low Pressure Boiler Operator must be able to define a boiler,
recognize the difference between a low and high pressure boiler, know
how to determine a boilers horsepower using heating surface and by
manufacture’s rating.

1.2 Boiler’s Heat

The Low Pressure Boiler Operator must be able to define heating surface,
sensible and latent heat, condensate, BTU, temperature, and explain a
typical feedwater system. The operator must be able to calculate the BTU
content of steam.

1.3 Combustion
The Low Pressure Boiler Operator must be able to identify the types of
heat transfer, define combustion, and the types of combustion such as
complete, perfect and incomplete. Also be able to identify the types of
draft for combustion and how they are produced.

1.4 Air
The Low Pressure Boiler Operator must be able to determine the amount
of air necessary for combustion and explain the term MATT.

1.5 Systems and Operations

The Low Pressure Boiler Operator must be able to properly operate and
maintain the feedwater, fuel, draft, and steam systems.

1.6 Design and Construction

The Low Pressure Boiler Operator must be able to describe the types of
boilers including fire tube, water tube, and cast iron sectional. Know the
meaning of the terms: maximum allowable working pressure, atmospheric
pressure, and absolute pressure.

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Body of Knowledge for Low Pressure Boiler Operator Exam for The State of Ohio

Part 2 Boiler Devices

Each boiler must have devices that ensure safe operation, this section will cover
these items that must be on every boiler.

2.1 Safety valves

The Low Pressure Boiler Operator must be able to test, and know the code
requirements of safety valves. Know the recommended care, size and
number of valves required. Be able to define capacity, set pressure, and
blow back. Must know the requirements for proper installation and
maintenance.

2.2 Steam gauges

The Low Pressure Boiler Operator must be able to test, maintain, and
determine proper size of gauges. The operator must also be
knowledgeable of the recommended care, installation, and calibration
procedures. The operator should know the difference between pressure,
vacuum, and compound gauges, and the meaning of steam gauge readings.

2.3 Water Column

The Low Pressure Boiler Operator must know how to change a gauge
glass. The operator must know how to test, maintain, and care for a water
column. The operator must know installation requirements and what
appliances can be attached to a water column

2.4 Blow down

The Low Pressure Boiler Operator must understand the care, maintenance,
and operation of the blow down system. Must also have knowledge of
installation requirements. Must also understand boiler water chemistry as
it relates to blow down.

2.5 Boiler Vent, Fusible Plug, Pressure Controls

The Low Pressure Boiler Operator must be able to operate, and know the
purpose of a boilers vent. Know the location, the recommended
maintenance, and the operation of a fusible plug. The requirements for
boiler controls and boiler pressure controls, installation, operation, testing
and types used must be thoroughly understood.

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Body of Knowledge for Low Pressure Boiler Operator Exam for The State of Ohio

Part 3 Feedwater Arrangement

Boilers must have an adequate supply of water to maintain safe operation.

3.1 The Low Pressure Boiler Operator must know the feedwater supply
arrangement including types, location of valves and devices used.

3.2 Condensate return/makeup systems

The operator must know how to maintain, operate, and test feedwater
regulators, low water fuel cutoffs, including evaporation test, and the
operation of automatic make up systems.

3.3 Pumps
The Low Pressure Boiler Operator must be able to operate, and maintain
boiler feedwater and vacuum pumps.

Part 4 Valves, Piping and Accessories

Boilers use piping systems to distribute steam and collect condensate for re-use in
the boiler.

4.1 The distribution of steam and return of condensate

The Low Pressure Boiler Operator must be able to operate, maintain, and
test steam valves and steam traps to ensure efficiency is maintained.

4.2 Steam Traps

The Low Pressure Boiler Operator must be able to operate, maintain, and
repair steam traps, and identify the testing methods for traps.

4.3 Return / non-return traps

The Low Pressure Boiler Operator must be able to tell the difference
between traps and identify how each type and style of trap operates and
where each is located.

Part 5 Heating Sources

Boilers require a heat source to generate steam. The Low Pressure Boiler
Operator must be able to describe the use of all fossil fuels and the
equipment used to handle, store, and combust these fuels.

5.1 Fuel oil

The Low Pressure Boiler Operator must be able to define flash point,
viscosity, fire point, pour point, atomization, and preheating.

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Body of Knowledge for Low Pressure Boiler Operator Exam for The State of Ohio

5.2. Fuel oil-burning equipment

The Low Pressure Boiler Operator must know the devices used from the
storage to the combustion of the fuel. Must be able to operate, maintain,
and test strainers, pumps, and heaters.

5.3. Gas
The Low Pressure Boiler Operator must be able to define Natural gas,
therm, gas pressure switch, low pressure and high pressure gas supply, and
combination gas and fuel oil burners.

5.4 Gas firing devices

The Low Pressure Boiler Operator must know the devices used from the
supply line to the burner, and must be able to operate, maintain, and test
this equipment.

5.5 Coal
The Low Pressure Boiler Operator must know each of the following;
stokers, hand firing, and smoke.

5.6 Stoker firing

The Low Pressure Boiler Operator should be able to operate, maintain and
bank stokers (underfeed, screw feed and ram feed types).

5.7 Firing Controls

The Low Pressure Boiler Operator must know the on/off controls,
modulating controls, microcomputer controls, flame system and operation,
programmer and its sequences. Be able to operate, maintain, and test firing
equipment, flame scanners, flame rod sensors, and photocell sensors.

5.8 Efficiency and Pollution

The Low Pressure Boiler Operator should be able to define primary
pollutant and secondary pollutant, and be aware of the 1990 Clean Air
Act.

Part 6 Draft
Moving the products of combustion through the boiler and discharging them away
from the operator.

6.1 The Low Pressure Boiler Operator should be able to define draft, and give
an example of the types of draft such as Natural and mechanical, including
the use of stacks.

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Body of Knowledge for Low Pressure Boiler Operator Exam for The State of Ohio

6.2 The Low Pressure Boiler Operator should understand the use of draft and
its benefits, be able to measure and control draft, know how to use a
manometer, analyze readings, and control and manipulate draft.

Part 7. Make up water and treatment

The applicant needs to know how adverse water conditions develop and be able to
recognize and treat these problems

7.1 Understand causes and affects of dissolved solids, scale, corrosion, and
caustic embrittlement.

7.2 The Low Pressure Boiler Operator should be able to control abnormal
operating conditions caused by adverse water conditions; perform water
treatment, water analysis, chemical treatment (internal), softeners and
deairators, (external) and blow downs.

7.3 The Low Pressure Boiler Operator should be able to analyze results of the
test, and chemically treat accordingly. They also need to maintain
softener operations and blow down boilers.

Part 8. Operating procedures

The Low Pressure Boiler Operator must know the steps necessary to prevent
damage to equipment and avoid personal injury, using the safety and operating
devices provided on the boiler.

8.1 The Low Pressure Boiler Operator taking over a shift must know how to
perform water column and gauge glass blow down, bottom blow down,
and test low water fuel cut off

8.2 The Low Pressure Boiler Operator should be able to perform boiler start
up, shut down, and normal operations, including valve line up, auxiliary
support equipment, monitoring and adjustments to fuel, air, water, and
pressures.

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Body of Knowledge for Low Pressure Boiler Operator Exam for The State of Ohio

8.3 The Low Pressure Boiler Operator needs to know the correct order of
events to effectively control abnormal conditions as rapidly and safely as
possible. Conditions to be remedied are: low water, high water, over
pressure, flame failure, furnace explosion, and feedwater pump failure.

8.4 The Low Pressure Boiler Operator needs to know the proper order for
boiler isolation, clean up, and preparation for inspectors visit, and
documentation of activity, Boiler inspection, tear down, preparation,
trouble shooting, hydrostatic test, and boiler room logs.

Part 9 Operating Safely

Adhering to safety guidelines and standards

9.1 The Low Pressure Boiler Operator needs to know the agencies and
services that are available such as OSHA, EPA, ASME

9.2 The Low Pressure Boiler Operator needs to practice safety at all times and
maintain a secure boiler room for all personnel involved. These boiler
room safety items include; fire protection, confined spaces, hazardous
materials, personal protective equipment, lock out – tag out.

Part 10. Laws and Rules

Ohio Laws and Rules pertaining to the licensing of Stationary Steam Engineers
and Boiler Operators and Low Pressure Boiler Operators

10.1 Horsepower by heating surface

10.2 License renewals

10.3 License revocation and expiration

10.4 Experience and schooling

10.5 Display of license

10.6 Requirements for boilers over thirty (30) horsepower by heating surface

Updated: 01/05/06