16 USACERL IR FE-95/03

The test examiners reported the following common weak areas of knowledge:
electricity, required wire sizes, refrigeration cycle, pump curves, boiler water level
control, boiler types, boiler blowdown requirements, water level checks, water
treatment, compressors, trigonometry, math

Operator Motivation and Knowledge
Operator Motivation

Most of the boiler operators displayed enthusiasm and interest in the course. A
few older operators indicated that they thought the course applied more to the
younger operators. Some of these older operators maintained that they would
retire if certification were too difficult a requirement. However, the majority of
operators were very interested and were observed helping each other study and
challenging each other with questions from the course material. Questions and
comments from the operators at the beginning of class each day indicated that
several of the operators studied the course material at night. There was complete
attendance even though many of the operators worked an 8-hour shift at night
after class. Some of the operators that missed the class due to working day shift
asked for extra instruction and course materials so that they could participate in
the examination.

Operator Knowledge

The operator baseline knowledge level ranged from poor to very good. At
installations where several of the operators had previously held local operator or
other state board licenses, the level of knowledge seemed higher. Additionally,
some of the operators with prior naval service as boiler operators scored better
than average. These individuals appeared to help maintain a higher level of
corporate knowledge at their particular installations. The improvement in scores
from the pre-test to the post-test indicated that the course had raised the
operators’ knowledge level. However, the decline in license exam scores as
compared to the post-test suggests that the pre-test and post-test examinations
were not as difficult for the operators as the actual fourth class examination
(Figure 1). Even though not all of the operators passed the NIULPE examination,
there appears to be sufficient determination and interest among some of those who
failed to indicate that they will continue to study and retake the examination.



USACERL IR FE-95/03

35.

37.

40.

In air conditioning systems, the primary principle is
a. rejection of heat
b. addition of cooling
c. addition of energy
d. thermostat setting

. A minimum of safety valves are required on all boilers of over 500

sq ft

Regge
ron

Sensible heat is heat that
a. can be measured with a thermometer
b. cannot be measured with a thermometer
c. is crested by pipe friction only
d. is unrelated to heating and refrigeration plant operation

. Fuses in electrical systems

a. prevent excessive current flows

b. open a circuit in the event of overheating
c. prevent damage to circuit components

d. all the above

. Which of the following combustion products is an indication of incomplete

combustion?
a. excess air
b. carbon dioxide
c. sulfur dioxide
d. carbon monoxide

On a fire tube boiler, the low water shut off valve __ in the event of low
water level.

a. opens the boiler drains

b. opens the boiler make-up valve

c. increases fuel flow

d. shuts off fuel flow



USACERL IR FE-95/03

12. The result of turbine water induction can be
a. turbine casing cracks
b. excessive vibration
c. rubbing of moving and stationary parts
d. all of the above

13. A power turbine is normally driven by
a. water

steam

feed water

the deaerator

the exhaust

i

14. The most functional way of removing corrosive oxygen (O2) is
a. chemical treatment
b. deaeration
c. spraying
d. superheating
e. boiling

15. A steam turbine normally exhausts into a
a. deaerator
b. feed pump
c. condensate pump
d. condenser

16. Condensate removed from a steam system is
a. worthless
b. in need of severe chemical treatment
c. recoverable
d. dirty
e. not economically salvageable

17. Relief valves are used primarily for relieving pressure in
a. liquid systems
b. gas or vapor systems
c. solids systems
d. steam systems



42

USACERL IR FE-95/03

12.

13.

14.

15.

16.

17.

The result of turbine water induction can be
a. turbine casing cracks
b. excessive vibration
c. rubbing of moving and stationary parts
d. all of the above

The critical speed of a turbine is the speed at which the turbine
a. rotor vibrates excessively
b. is ready for loading
c. reaches the overspeed limit
d. none of the above

The most functional way of removing corrosive oxygen (Og) is
a. chemical treatment

deaeration

spraying

superheating

boiling

sae

The viscosity of a fuel oil refers to its ability to
a. burn
b. flow
c. lubricate
d. seal

Condensate removed from a steam system is
a. worthless
b. in need of severe chemical treatment

c. recoverable
d. dirty
e. not economically salvageable
Safety valves are used primarily for relieving pressure in
a. fluid systems
b. gas or vapor systems
c. solids systems
d. steam systems



10 USACERL IR FE-95/03

several DOD personnel offices were contacted to investigate the mechanisms for
implementing a boiler operator certification program.

The skills and knowledge required of boiler operators were independently
reviewed. CEP operation and maintenance (O&M) training methods, and the
resources and reference materials available in the government and private sector
were identified and reviewed, including self-training methods and materials. A
literature collection in the library of the National Association of Power Engineers
(NAPE) used by that organization to prepare its members for certification was
reviewed, and the materials forwarded to the participating DOD installations.

A sample course was designed and given at various DOD installations. Course
effectiveness was evaluated by administering a pre-test and, at the course's
conclusion, a post-test and the NIULPE Fourth Class Power Engineer exam, and
by comparing the results from the exams. Conclusions were drawn from the
objective test results and from the subjective experience of administering and
taking the engineering course, and recommendations were made for creating a
program to train and certify boiler operators.

Mode of Technology Transfer

The information in this report will be used to support the continuing education
and training program the Army has established through USACPW. At the time
of this publication, USACPW has contracted to provide operators of Army
installation central energy plants NIULPE 4th Class training and certification.
It is recommended that the final results of this study be incorporated into Army
Regulation (AR) 420-15.



70

USACERL IR FE-95/03

Receive immediate feedback on wrong answers and information on where to find the
correct answer.

The ability to mark a question that may be wrong or ambiguous so that the test
manager can review that question.

The ability to submit draft questions to the test manager for review and possible
inclusion in the test bank.

Recording of progress in multiple curriculum with the completion of a single question.
The ability to access CD-ROM reference materials while in the CHPTUTOR

Manager:

The ability to view overall progress across all curriculum for an individual and a
group.

The ability to view overall progress across all certification levels or CDC books for an
individual and a group.

The ability to view progress within a certification level or CDC book for an individual
and a group.

The ability to view progress within a certification knowledge area or CDC book chapter
for an individual and a group.

Print out a listing of weak knowledge items and precise locations of the correct answer
for an individual.

Legible question screen with graphic representation possible.

The ability to add, delete or edit locally produced questions.

The ability to flag erroneous force produced questions so that the system will not call
on the question.

The ability to mark a question that may be wrong or ambiguous so that the force test
manager can review that question.

The ability to submit draft questions to the force test manager for review and possible
inclusion.

The ability to add references for all questions.

The ability to specify access to a CD-ROM reference for all questions.

The ability to add, edit or delete references for local questions.

The ability to import an updated force question bank or new force curriculum to the
system.

The ability to import local questions from other bases into the local question bank.
Menu access to the standard flags so that locally produced questions are compatible
force wide if approved.

The ability to add or delete flags to local questions when viewing a question.

The ability to add flags to any current question when viewing a question.



52

USACERL IR FE-95/03

units. Removes old and installs new equipment. Units and
systems services are designed requiring few testing techniques to
locate worn or broken parts; repairs are not normally complicated
by need for specialized equipment. 45%

Performs other duties as assigned.
1. Knowledge/Skill (continued):

complicated commercial and industrial heating units and systems.
Requires thorough knowledge of principles of methods of combus-
tion, ratios and arrangements of heating surfaces, distribution
and ocnstruction of large complex heating units and systems.
Skilled in completing complex repair/replacement procedures.
Knowledge and skill to observe, test heating equipment, localize
malfunctions and determine and carryout action necessary to
correct malfunction. Utilizes pipefitter/plumber mechanic skills
in repair of gauges, heaters, tests instruments, probes use in
water measuring and testing and electrical knowledge of semiauto-
matic boiler firing and control devices, limiting and safety
switches, pumps, heaters and meters. Uses mathematics on a
continuing basis employing percentage, ratios, measuring units,
laboratory terms and metric measurements.

2. Responsibility:

Works under very general supervision of immediate supervisor and
the General Foreman, Climate/Kitchen Equipment Shop. Receives
verbal instructions, service orders or work orders outlining in
general terms equipment deficiencies and extent of work to be
accomplished. Independently performs duties in accordance with
established procedures, technical manuals and manufacturer's
specifications. Is responsible for taking boiler water, cooling
tower, and closed system samples and providing chemical treatment
to maintain boilers, cooling towers and dual temperature closed
system. Determines if unexpected results from tests are caused
by system malfunctions. Supervisor reviews work in terms of
boiler, cooling tower, and dual temperature closed system
condition and results of treatment as reported by boiler inspec-
tor and visual inspections. Supplemental instructions such as
blueprints, sketches, specifications are provided as necessary.
Determine own work methods, plans sequence of work and is
responsible for overall accomplishment using full range of trade
techniques and work methods. Work is spot checked during
performance or upon completion for satisfactory workmanship.



50

USACERL IR FE-95/03

Job Description #19579
Major Duties (continued):

approximately 25 cooling tower systems ranging in size from 40
tons to 1200 tons capacity for regulating cycles fo concentration
based on conductivity or chlorides. Adjust chemical feed pumps
and bleed rates continuously to maintain acceptable cycles.

a. Performs chemical analytical tests: Perform chemical
analytical tests for sealing tendency, turbidity, hardness,
alkalinity, fret mineral acid. carbon dioxide, pH, sulfate,
sodium sulfite, chloride, nitrate, glycol, sodium silica, iron,
manganese, aluminum, oxygen, hydrogen sulfide, ammonia, dissolved
solids, conductivity suspended solids and total solid or selected
test as suitable to maintain stable chemical concentrations.
Collects and analyzes water samples from chilled water, hot water
and dual temperature heating and cooling systems, steam systems,
steam condensate return systems and cooling towers systems for
specified chemical concentration for the respective system.
Diagnose and prescribe chemical treatment needed to return water
in its respective system to proper chemical concentration.
Collect and analyze water samples from the domestic water
supplies for chlorine residuals.

b. Performs inspection tasks: Inspects piping, valves, tank,
pumps associated with water condition system. Make standard
corrosion test on condensate return systems and make required
chemical treatments to reduce or eliminate corrosion problems in
the piping systems.

Inspects boiler to determine the need for chemical cleaning.
Performs qualitative and quantitative statistical analysis to
establish trends, mean and standard deviations. Analyzes the
statistical results for probable cause and variance.

Cc. Performs related tasks: Establishes boiler blowdown
intervals or rates for manual of automated systems respectively.
Adjusts bleedrates on cooling tower to maintain proper cycles of
concentration (COC).

Maintains records to reflect daily test results and chemical
added to water systems. Submits monthly reports as required by
current regulations. Provides monthly water samples to for
quality assurance correlation testing. Secures needed laboratory
chemical to conduct test. Maintains test equipment and work area



56

USACERL IR FE-95/03

| Wednesday

Pump/Inj
Pump/Inj
| Steam/Pipe
‘SteamyPipe

Review

; Thursday
| Safety,

Logs/Regs
Logs/Regs

Logs/Regs

Review

Feedwater, Corrosion and Water Treatment

Steam System and Steam Piping
Boiler Operations and Maintenance

Air Conditioning, Refrigeration and Air Compressors
Logs, Log Review, Inspections and Regulations

Time | Monday Tuesday

14:30 {2 B. Features _ Grate/Brnr

15:00 B. Features Grate/Brnr

15:30 | B. Features Grate/Brnr

16:00 | B. Features Comb/Poll

16:30 | Review Review

Legend:

B. Features Boiler Features
Grate/Brnr Boiler Grates and Burners
Comb/Poll Combustion and Pollution
B. Controls Boiler Controls
FeedW/Chem

Pump/Inj Pumps and Injectors
Steam/Pipe

Ops/Maint

Elect Electricity

AC&R

Logs/Regs

Friday
NIULPE
| NIULPE
NIULPE
NIULPE
Admin



60 USACERL IR FE-95/03

Appendix G: Fourth Class Power Engineer
Study Guide

Below is the NIULPE Curriculum and the locations in the complete NAPE library that
address those topics. The numbers refer to the NAPE publication number that
contains the topic information. Please note that NAPE publication numbers 1, 2,
15, 16, 19 and 22 are bound together for the operator’s convenience in a book
named “National Association of Power Engineers (NAPE) Boiler Operator Course and
Certification Study Questions.” This single book should provide a reasonable
substitute for access to the whole NAPE library. Feel free to copy this list and
distribute it to your operators.

NIULPE

Topic

Suggested NAPE Library

Number Publication Number and Page Numbers

1. Water glass: Placement, function, how held in place, length, maintenance, valves
needed, replacement, how and when teseted.
22: p.8; 25: Lesson 6, p.14-22; 26: p.31-33; 27: p.25-29,30;
30: p.227-233

2. Water column: Placement, function, how held in place, length, care, what could
affect its efficiency, maintenance, valves and cocks, how and when tested.
22: p.7,8; 25: Lesson 6, p.14-22; 26: p.81-33; 27: p.25-29,181;
30: p.227-233,296

3. Safety valve and rupture discs: Placement, principle, function, care,
maintenance, potential failures, how and when tested.
1: question 13; 15: questions 79,116,117,198
16: Elem. questions 5,8; 19: questions 46,59,60 22: p.8,28
25: Lesson 6, p.9-14; 26: p.22-27,41,42,182;
27: p.21-24; 30: p.243-252,284,305,502-504,565



48

USACERL IR FE-95/03

48. Solenoid valves use

a.

b.
c.
d.

to operate.

manual levers
pneumatic actuators
electro magnetism
electric motors

49. In the operation of a safety valve, the term “blow down” refers to

50.

a.

“db.

c.
d.

pe ep

the pressure at which the valve opens

the difference between valve opening and closing pressures
the pressure at which the valve closes

the volume of gas released by the valve when it is open

can be found by multiplying volts and amps.
Ohms
Hertz
Watts
Resistance



20 USACERL IR FE-95/03

4 Further Work

Standard Boiler Operator Training Course

The U.S. Army Center for Public Works (CECPW) has established an indefinite
delivery order to procure 5-day training courses for Army installations to provide
NIULPE Fourth Class training and certification. The specifications for the courses
were based on the results of the successful pilot program courses. Appendix E is
a sample course schedule and budget that was used in the contract documentation
for some of the successful courses and the CECPW delivery order. The CECPW
delivery order will give the field managers a mechanism to procure more courses
for their installations. It would be useful to closely monitor the reception of the
course in the field and to continue to measure the results from the 1-week courses
to identify training weaknesses that need remediation by other means. Although
the pilot program has shown that a 1-week course alone can not rectify all training
deficiencies, the course can be a valuable part of an installation’s continuing
education and training program.

Specifications for any training course should be detailed enough to ensure that
training is carried out efficiently. The CECPW course and any other future course
should show the characteristics of the successful courses in the pilot program.

Course Learning Objectives

The course should cover the topics listed in the NIULPE Fourth Class Power
Engineer Curriculum (Appendix F). The only learning objective not mentioned by
name in the NIULPE standard is the training on the legal requirements
pertaining to boiler operations on DOD installations. It is important that the
course address these requirements in the syllabus.

Course Structure

The course should cover the NIULPE topics in an orderly fashion balancing review
with new material each day. Based on operator feedback, it is recommended that
some of the more difficult topics such as electricity and refrigeration equipment
be covered early in the course to afford the instructor opportunity to conduct extra
review or to allow operators time to study on their own. The model course



38

USACERL IR FE-95/03

Al.

42.

43.

45.

46.

A pump pumps 300 GPM. If it runs for an hour it will pump
1,800 gallons

18,000 gallons

180,000 gallons

1,800,000 gallons

ae rp

In a fire tube boiler, the flue gases flow through the
a, furnace area
b. the boiler tubes
c, the windbox
d. the water tubes

Heating number 6 fuel oil
a. makes it thicker
b. increases its viscosity
c. decreases its viscosity
d. increases it pour point

. A gauge pressure reading of 14.7 psig is equal to an absolute pressure reading

of what?
a. 24.7 psia
b. 0 psia
c. 14.7 psia
d. 29.4 psia

If a boiler has 10,500,000 BTUs of heat input every hour and the steam
leaving the boiler every hour contains 9,500,000 BTUS, the boiler has an
efficiency of
a. 100%
b. 95.5%
ec. 90.5%
d 9.5%

What is the purpose of an economizer section of a boiler?
a. To recover flue gas BTU's leaving the boiler
b. To preheat boiler gas before pollution control
c. An economizer preheats primary or secondary air
d. An economizer is used to increase secondary superheat temperature



USACERL IR FE-95/03

69

training programs will increase training productivity since multiple training goals will
be met with a single effort. The question bank will also have sufficient flexibility to
direct the student to the precise location in a training resource for corrective study.
Additionally, the system's ability to track multiple training objectives and precisely
direct the operator's study effort will allow use of this product with other existing DOD
training curriculums. Successful utilization of this product may warrant its use with
other DOD or industry training programs.

4. APPROACH: This product will be an adaptation of the existing USAF testing aid
CERTEST. The question bank architecture will be expanded to provide flagging for
access by multiple curriculums and to provide documentation of the location(s) of the
correct answer. The curriculum manager will have screen options added to assist in
editing and creating curriculums and tutorial programs.

TASKI - DRAFT SYSTEM ARCHITECTURE: A schematic will be developed of the
tutoring system. The structure will be checked for compatibility with the existing
CERTEST system so that modifications can be identified. The structure will be
compared with the NIULPE curriculum, the USAF CDC 54550 series curriculum and
at least one other curriculum or training standard currently used in DOD.

TASK II - CERTIFICATION TRAINING CURRICULUM DOCUMENTATION: The
current NIULPE and CDC curriculum and study questions will be reviewed.
Questions and question references will be selected for inclusion in the training system.
The questions will be constructed to meet the format requirements of the training
system. Copyright permissions will be secured as necessary.

TASK III - DRAFT USER AND MANAGER INTERFACE: Diagrams and schematics
of student and curriculum manager interfaces will be produced. Screen representa-
tions will be chosen to meet the interface requirements. The following interface
requirements should be met:

Student:

The ability to view overall progress across all curriculum enrolled in.

The ability to view overall progress across all certification levels or CDC books.

The ability to view progress within a certification level or CDC book.

The ability to view progress within a certification knowledge area or CDC book
chapter.

Printout a listing of weak knowledge items and precise locations of the correct answer.
Legible question screen with graphic representation possible.



REPORT DOCUMENTATION PAGE Come Mor ovoe 0188

Public reporting burden for this collection of information is estimated to average 1 hour par response, including the time for reviewing instructions, searching existing data sources,
gathering and maintaining the data needed, and completing and reviewing the collection of information. Send comments regarding this burden estimate or any other aspect of
this collection of information, including suggestions for reducing this burden, to Washington Headquarters Services, Directorate for information Operations and Reports, 1215
Jetterson Davis Highway, Suite 1204, Arlington, VA 22202-4302, and to the Otfice of Management and Budget, Paperwork Fleduction Project (0704-0188), Washington, DC 20503,

T. AGENCY USE ONLY (Leave Blank) | 2. REPORT DATE 3. REPORT TYPE AND DATES COVERED
November 1994 Interim
%._TITLE AND SUBTITLE 5. FUNDING NUMBERS:
The Department of Defense Central Heating Plant Operator Training and 4A162784
Certification Program: An Overview AT45
EB-XK3
6. AUTHOR(S) MIPR(s)
Michael K. Brewer and Ralph E. Moshage E87420477 and
N0002593MP006M
7. PERFORMING ORGANIZATION NAME(S) AND ADDRESS(ES) (8. PERFORMING ORGANIZATION
U.S. Army Construction Engineering Research Laboratories (USACERL) REPORT NUMBER
P.O. Box 9005 FE-94/Draft
Champaign, IL 61826-9005
3. SPONSORING / MONITORING AGENCY NAME(S) AND ADDRESS(ES) 10, SPONSORING / MONITORING
U.S. Army Center for Public Works (USACPW) AGENCY REPORT NUMBER

ATTN: CECPW-EM
77101 Telegraph Road
Alexandria VA 22310-3862

17, SUPPLEMENTARY NOTES
Copies are available from the National Technical Information Service, 5285 Port Royal Road, Springfield, VA 22161.

"12a, DISTRIBUTION / AVAILABILITY STATEMENT ¥2b. DISTRIBUTION CODE

Approved for public release; distribution is unlimited.

13. ABSTRACT (Maximum 200 words)

The variety of equipment found in Department of Defense (DOD) central energy plants (CEPs) and the complexity of
these plants demands that CEP operators be highly qualified personnel. Given the serious danger posed by improperly
operated boilers, similar operations in the private sector have long maintained processes to establish credentials for
their employees. The 1990 Clean Air Act Amendments (CAAA 1990) also recognize the importance of trained and
certified fuel plant operators toward improving air quality. As a result of CAAA 1990, the U.S. Environmental
Protection Agency (USEPA) will eventually require all operators of boilers with capacities greater than 10 million BTU
per hour (298 Boiler HP) to be trained and certified.

A DOD-wide training and certification program for CEP operators needs to be developed and implemented to increase
the safety and reduce the energy and environmental cost of operating central energy plants, and to meet the CAAA
1990 requirements. This study examined the training needs of central energy plant operators at DOD installations to
identify the resources required to meet those needs and to assess their effectiveness in the field.

14. SUBJECT TERMS 15. NUMBER OF PAGES
central heating plants 89
operator training and certification 76. PRICE CODE
17. SECURITY CLASSIFICATION 18, SECURITY CLASSIFICATION 79, SECURITY CLASSIFICATION 20. LIMITATION OF ABSTRACT
OF REPORT OF THIS PAGE OF ABSTRACT
Unclassified Unclassified Unclassified SAR
ISN 7540-07-280-5500 lard Form 298 (Rev. 2-89)

Prescribed by ANSI Std 239-18
298-102



72

USACERL IR FE-95/03

d. One (1) local test manager will not be briefed but will be given only a draft guide
booklet and will add, edit and delete local questions provide by USACERL. The local
test manager will also be given a simulated force update disk to load into the system.
The local test manager will input simulated proposed questions to the force manager
for review. The local test manager will view all the manager screens and offer
comments. The manager will conduct these procedures without any coaching.

e. A-simulated force test manager will review proposed force question bank additions
or corrections and will make the changes, additions and deletions required.

f. One local test manager will send some of his local question to the other local test
manager. The receiving local test manager will install the imported questions and
adjust the flagging of those questions.

TASK VII - ALPHA VERSION CRITIQUE: The comments and observations
produced in TASK VI will be reviewed and collated into an interim report. Recommen-
dations will be developed for implementation in the Beta version of the system.

TASK VIII - BETA VERSION DEVELOPMENT: The recommendations developed
from TASK VI and TASK VII will be incorporated into the system structure.

TASK IX - BETA VERSION TEST BANK LOADING: The curriculum questions
selected and developed in TASK II will be inserted into the system. If the modifica-
tions occurring in TASK VIII allow, the question bank loading can be concurrent with
the beta version developments.

TASK X - BETA VERSION TESTING: The prototype system will be tested at a
minimum of two (2) DOD installations. The test program at each base will consist of
at least the following:

a. Approximately one third (1/3) of the operators will be randomly tasked to take a
pre-test similar in scope to the NIULPE Fourth Class Power Engineer examination
prior to delivery of the system to establish a knowledge benchmark.

b. The system will be shipped the bases for utilization. The bases will be given a time
period of twelve (12) weeks to use the system.

c. At the end of the trial period a post-test will be given to the same operators who
took the pre-test to measure knowledge base increase.

d. At the end of the trial period all the operators will be given the NIULPE Fourth
Class Power Engineer examination. The pre-test and post-test participant's
performance will be segregated to measure any bias since they had extra test taking
experience.



USACERL IR FE-95/03

71

The ability to view a list of a test or test section.

The ability to assign a descriptive label to a locally produced question so that the
entire question list may be viewed.

The ability to view the entire question list by sort or sorted view options.

The ability to access a question from a list.

The ability to view the flagging options of a particular question or group of questions
while viewing a question list.

The ability to add or delete flags to a particular question or group of locally produced
questions while viewing a question list.

The ability to view the question selection criteria when viewing the list of a test or test
section (i.e., 2 of 6 questions will be chosen).

The ability to print out tutorial questions.

The ability to assign descriptive names to augment the alphabet letter test section
name.

TASK IV - ALPHA VERSION STRUCTURE DEVELOPMENT: The first system
version to meet the specifications of TASK I, TASK III and paragraph 5 will be
developed.

TASK V - ALPHA VERSION QUESTION BANK LOADING: The technical
information for at least four (4) NIULPE curriculum topics, a NIULPE simulated test
and one (1) chapter of a heating USAF CDC will be loaded into the program structure.

TASK IV - ALPHA VERSION TESTING: The prototype system will be tested at a
minimum of two (2) DOD installations. The test program at each base will consist of
at least the following:

a. Five (5) operators will be briefed on the use of the system and will complete at least
two (2) modules and a final test. Each of the operators will enter a draft question
proposal and erroneous question alert for the local test manager.

b. Five (5) operators will not be briefed but will be given only a draft guide booklet
and will complete at least two (2) modules and a final test without any briefing or
coaching. Each of the operators will enter a draft question proposal and erroneous
question alert for the local test manager 1

c. One (1) local test manager will be briefed on the use of the system and will add,
edit and delete local questions provide by USACERL. The local test manager will also
be given a simulated force update disk to load into the system. The local test manager
will input proposed questions to the force manager for review. The local test manager
will view all the manager screens and offer comments.



74

USACERL IR FE-95/03

d. Two test banks, force and local.
e. Two types of question banks, secure and unreferenced (CERTEST), and, tutorial

and referenced (CHPTUTOR)
f. Three tiered system structure similar to CERTEST

Example:
CERTEST NIULPE USAF CDC
Shops Operator Class CDC Book Volume
Tests Curriculum Knowledge Area CDC Book Chapter
Section Knowledge Goals . CDC Knowledge Objectives

g. At least 3 curriculum flags on a question, NIULPE, CDC, and one reserved for
future use. The question structure should have sufficient flexibility to add a fourth

flag without major system reconfiguration.

h. Each “test” module should be small enough to complete in 15-20 minutes.

i. Completion of a question shared by multiple curricula would be recorded on each
curriculum list in the student’s record of progress file.

j. The test question should tell the operator he was wrong and refer the operator to
a publication to find the right answer. It should not tell the operator the right answer.
It should allow the operator to access a CD-ROM reference document while in the

tutorial.
k. The study questions should come from NIULPE, National Association of Power
Engineers (NAPE), USAF CDC and other DOD training materials.

1. User's guide book.

m. Local test manager's guide book.
n. Force test manager's guide book.
6. COST ESTIMATE: TBD

TASK
EXPENDITURES

7. COMPLETION TIME:

The final task, TASK XIV, will be commence 15 months after the award of the

contract.



USACERL IR FE-95/03

37

Appendix C: Boiler Operator Training Tests

Fourth Class Operator Pretest

1.

Proper combustion of oil produces a flame in the color of
a. yellow
b. green
c. red
d_ blue
The primary function of bottom blowdown is to
a. remove sludge
. remove excess water

b.
c. remove excess chemicals
d. relieve excess pressure

The first duty of an engineer coming on duty is
a. check boiler temperature
b. check boiler water level
c. check boiler pressure
d. check for boiler leaks

Heat transfer methods are
a. radiation, reflection, infiltration
b. convection, radiation, lumens
c. as defined in ASHRAE 63-1989
d. radiation, convection, conduction
e. combustion, convection. radiation

Boiler feed water control is
a. to control pressure
b. to control temperature
c. to control safety valves
d. to control water level



USACERL IR FE-95/03

17

100 =

| —O— High
| —4$§-- Mean
--fke-- Low

90 4
80

70
60
50

Test Score (%)

40
30
20

10

0

Pre-Test

Post-Test

NIULPE

Plant Management and Operations

Engineering Management and Leadership

Figure |, Boiler operator score data.

At all installations the supervisory personnel were enthusiastic and supportive of
the boiler operator training. The plant management did a superb job in arranging
classroom facilities and allowing tours of the plants. The plant management was
very interested in the training and willing to adjust the work schedule to support

the training.

Plant Operations

The general condition of the central heating systems ranged from fair to excellent.
Although the scope of the visit was not to inspect the plants, the tours of the plant
revealed some discrepancies that were acted on by the personnel present. The
tours were conducted to provide a laboratory lecture and allow the students to

explain the operation of their plant as an educational exercise.



USACERL IR FE-95/03

23

NAPE Library

Operators should have materials available to help further their technical
knowledge. It is recommended that installations establish training libraries in the
heating and cooling shops where no such a library currently exists. An excellent
start would be the NAPE library collection (Appendix B) and a subscription to the
National Engineer, the professional magazine of NAPE.

Boiler Operator Study Book

As mentioned above, a single study book to assist the motivated operator to
prepare for certifications would be useful. Several of the NAPE publications would
be good candidates for such a book. Development of the study guide may be a
good opportunity to partner with industry and professional educational organiza-
tions such as NAPE to produce a mutually beneficial training tool.

Computer-Based Tutor (CHPTUTOR)

The presence of computers in central heating plants for administrative functions
may provide another avenue to deliver training. The U.S. Air Force CERTEST
program has been eagerly accepted as a training product. The primary criticism
from the field is the lack of feedback on incorrect answers and the lack of
referencing to the source of the correct answer. Although the purpose of
CERTEST is only to test and not to train, these modifications would be achievable
with the present product. USACERL has drafted a proposal (Appendix I) to
modify the current CERTEST into a tutoring tool. The computer tutor could guide
the student through each of the NIULPE topics at the students pace. Incorrect
answers from the student would elicit a response and direct the student to the
precise location in a study book, technical manual, training videotape or operating
code book to find the answer. On completion of the training module, the student
would take a test using the original CERTEST software architecture to protect the
integrity of the CERTEST test bank. Additionally, the student could be given the
opportunity to take a simulated NIULPE examination to help prepare for the
actual NIULPE examination. Such a system could document operator progress as
well as help direct the self-study efforts of operators.

Formal Continuing Education Classes

Licensed operators should have opportunity to participate in continuing education
to maintain their proficiency. Installations should consider conducting 1 day in-
house training classes quarterly or semi-annually to update operators and
reinforce good operational practices. Additionally, installations should consider



USACERL IR FE-95/03

19

of some examiners to discuss the problems and successes each operator experi-
enced with the test had a positive effect on the morale of the class.

Certification Implementation

USACERL initiated discussions with the Office of Personnel and Management
(OPM) and some DOD personnel offices to investigate the mechanisms for
implementing a boiler operator certification. The primary mechanism that has
been used to enforce and implement certifications in other federal positions has
been the terms of employment and position description (Appendix D). OPM has
advised the DOD not to make licensing or certification a wage grade issue. OPM
recommends that any certification be a condition of employment to meet minimum
safety, health, or environmental requirements. Experience has shown that
certification has already been successfully enforced with these mechanisms for
welders, water treatment plant operators, and nondestructive testing technicians.
OPM discussed a case with USACERL in which the failure of a welder to maintain
a certification resulted in reassignment of that person to a position not requiring
such certification.



32

USACERL IR FE-95/03

6. Ican continue to run my boiler

a.

goer m

7. The most important safety feature of my boiler is

a.

b.
.
d.

8. The primary cause of a furnace explosion is

a.

b.
.
d.

with a tube failure

with a steam drum leak
with a safety valve blowing
with a gauge glass broken
with refractory failure

the burner switch

the safety valve

the fuel pressure regulator
the flame control

low water

high chlorine
combustible gas build-up
leaking steam drum

9. Eccentricity is a measure of

a.

b.
c.
d.

shaft vibration

. shaft alignment

shaft straightness

. all of the above

10. An economizer functions as

a.
b.
c.

d.

an air preheater

a superheater

a regulator

a feedwater preheater

11. A soot (tube) blower should be operated

a.

coo

when windy conditions exist
only when firing with coal

daily

once per shift

when required, see manufacturer


14 USACERL IR FE-95/03

3 Program Results

Course Performance

Courses were given at five Army installations and three Navy bases. The
programs conducted at the installation are to measure the validity of the NIULPE
standard and the effectiveness of a refresher course. The reception of the program
in the field was very positive. The program consisted of conducting a course,
testing the operators, observing the plant, and interviewing the personnel.

Pre-Test

All the boiler operators were given a pre-test consisting of 40 to 81 multiple choice
questions similar is complexity to the questions on the National Institute for the
Uniform Licensing of Power Engineers (NIULPE) Fourth Class Operator exam
(Appendix C). This exam helped establish a knowledge base for curriculum
assessment. Table 1 summarizes the combined results to date.

Table 1. Pre-test results.

Parameters Results
Number of operators 125 (1 operator on leave, 6 supervisors unavailable)
Mean Score 64.2

Standard Deviation (middle 68 percent) | 16.0

Median Score 64

High Score 98

Low Score 12.5
Post-Test

All the boiler operators were given a post-test near the end of the 44-day course,
which also consisted of 40 to 81 multiple choice questions similar is complexity to
the questions on the NIULPE Fourth Class Operator exam (Appendix C). The
examination provided feedback on student information retention. The post-test



USACERL IR FE-95/03

Topic : : Tape Number PIN
Transformer Maintenance E-22 802917 DN
Maintenance of Low Voltage Circuit Beaker

and Switchgear _ : ee E-23 - 80291 8 DN
Instrument Transformers - ; E24 802919 ON
Maintenance of High Voltage Circuit Beaker

and Switchgear E-25 802920 DN
Storage Batteries and Chargers E-26 802921 DN
Cables, Conductors, Splices, and Terminations 1 E-27 802922 DN
Cables, Conductors, Splices, and Terminations 2 E-28 802923 DN
Conduit Installation i E-29 802924 DN



USACERL IR FE-95/03

e. At the end of the trial period all the operators at one (1) similar non-participating
base will be given a NIULPE examination to provide a control sample group.

f. Interviews will be conducted at the participating bases to obtain feedback of the
system's performance.

TASK XI - BETA VERSION CRITIQUE: The comments and observations produced
in TASK X will be reviewed and collated into an interim report. Recommendations
will be developed for implementation in the Gamma (final) version of the system.

TASK XII - GAMMA (FINAL) VERSION DEVELOPMENT: The recommendations
developed from TASK X and TASK XI will be incorporated into the system structure.

TASK XIII - GAMMA VERSION TEST BANK LOADING: The curriculum questions
selected, developed and loaded in TASK II and TASK IX will be inserted into the
system. If the modifications of TASK XII allow, the question bank used for the beta
testing can be loaded into the gamma version. Question content modifications
necessary based on comments in TASKS V, VI, X and XI will be implemented as well.

TASK XIV - GAMMA VERSION DELIVERY AND FINAL REPORT: The gamma
version will be delivered to the bases as specified by each of the services within DOD.
A final report will be produced documenting the work conducted in TASKS I to XII.
Recommendations for other applications of this system within the DOD will be
included in the report.

5. PRODUCT OF RESEARCH: The final product will be a computer based tutoring
system to prepare central heating plant operator and supervisor for certification. The
system will generate study questions for each curriculum subject necessary for a
particular class of certification. The design of the question bank must have the
flexibility to be addressed by at least two other similar training curriculums such as
USAF Career Development Courses (CDC’s) or USN Personnel Qualification System
(PQS). The ability to track progress in similar training programs will increase
training productivity multiple training goals will be met with a single effort. The final
product will have a question bank to address (5) five levels of certification similar to
the certification levels designated by the National Institute for the Uniform Licensing
of Power Engineers (NIULPE).

Specifications:

a. Interfaces and capabilities described in TASK III.

b. The identity of the student would be consistent across all curricula
c. Two levels of test manager, local and force.



58

USACERL IR FE-95/03

16.

17.

18.

19.
20.

21.

22.

23.

24,

25.

26.
27.

28.

29.

30.

31.

Elementary combustion: Mixtures of combustibles and air, methods of application
and how controlled, purpose of setting, dampers, draft, chimneys or stacks, hand
firing methods, heating values of anthracite or bituminous coal, oil and gas.
Pumps-simplex, duplex, vacuum: Care, maintenance, purpose, potential failures,
remedies, description.

Injector: Function, principle, care, maintenance, cleaning and inspection, how
often, purpose, valves.

Cleaning and inspection of boilers and setting.

Starting clean boiler: Manhole covers, how replaced and removed, raising steam,
cutting into live steam header, banking boiler and starting after bank.

Grate surface, fire line, water level, fire tubes, water tubes, heating surface:
Meaning of these terms.

Operation of stoker: Starting, purpose, maintenance, care, potential failures,
advantages and disadvantages.

Operation of oil or gas burners and electric boilers: Installation, starting, care,
possible failures, controls, safety devices.

Steam non-return valve, expansion joints, heaters, steam separator, sight feed
lubricator, steam trap reducing valve, feed water regulator: Function, use and
location.

Refrigeration compressor, condenser, receiver, evaporator, purge, expansion valve,
charting, liquid, suction, discharge, cross-over valves: Purpose, location, dangers,
correct operating procedures.

Air compressor: Dangers in operation, maintenance, correct operating procedure.
Electrical equipment: Fuses, cut outs, relays, switches, circuit breakers, purposes
and comparative applications. Dangerous conditions in operation of a motor.
Prevention of starting. Sizes of fuses. Carrying capacities of wires for lighting
circuits. Volt, ampere, watt, Ohm, D.C., A.C., electrical conductor, electrical
insulator: Meaning of these terms. Difference between electric generator and
motor.

Steam Engines: Types, setting valves, purpose of 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.

Steam turbines: General knowledge of the lubricating system, governors, and
throttle valves.

Steam condensers: General knowledge of condensers, where, how and why they
are used. General care and upkeep of condenser auxiliaries.

Steam plant accessories: Back pressure valves, non return valves, throttle valves,
expansion joints, feed water regulators, steam separators, sight feed lubricators,



USACERL IR FE-95/03

Appendix B: NAPE Library List... .. 2.6.6... eee eee eee eee 29
Appendix C: Boiler Operator Training Tests ........ 0.500. e eee ee eee eee 31
Appendix D: Sample Job Description Worksheet ......... 6. cece eee eee eee 49
Appendix E: Fourth Class Power Engineer Course Schedule .............-..+5- 54
Appendix F: NIULPE Fourth Class Power Engineer Curriculum .........-+.+-+-- 57
Appendix G: Fourth Class Power Engineer Study Guide ......-...--.2-- +e eee 60
Appendix H: Sample CHPTUTOR Software Architecture .......--.--+ sees eee 66
Appendix I: CHPTUTOR Draft Proposal ......-. 0. esse eee eee 68
Appendix J: Qualifications Needed for NIULPE Certification .......-....-.eee eee 76
Appendix K: NUS Tape Ordering Procedure ........-. 5-2 seer eect teen eee 79

Distribution


USACERL IR FE-95/03

Appendix B: NAPE Library List

The publications included in the following list are taken from the NAPE
Engineering Library and the are available by mail order. To order, indicate
publication number and mail order to:

National Engineer
5-7 Springfield Street
Chicopee, MA 01013
Ph: 413-592-6273
FAX: 413-592-1998

Number | Publication Name Cost
1 Boiler Plant Operation, by Woodrutt $3.50
2. Electric Motors and Generators $3.50
3. Refrigeration $3.50
4. Combustion $3.50
5. Fundamentals of Air Conditioning $3.25
6. Fuel Oil and Its Combustion, by Roulton $4.50
7. Automatic Combustion Control, by Lammers $3.50
8. Fundamental of Heat, by Hiss $3.00
9. Modern Boiler Plant Management $3.25
10. How To Establish Power Plant Operating Records and Costs, by Dick $3.00
W. How To Run a Boiler Test, by Moe $3.00
12. Flow of Steam and Water in Piping $3.00
13. Engineering Investigation and Reports, by Roulton $3.00
14. Steam Turbine Operation and Maintenance, by Allen $3.00
15. Engineer's 1Q $3.25
16. Typical Questions for Engineer's License Examinations $2.85
17. Study Questions on Boilers and Combustion $3.00



USACERL IR FE-95/03

29.

30.

31.

32.

33.

34.

35.

Steam turbines: General knowledge of the lubricating system, governors and
throttle valves.

14: p.1-6; 15: question 64; 19: questions 255, 256, 257, 259, 268, 270, 272, 280,
281, 295, 296, 302, 320; 22: p.25, 39; 30: p.473-525

Steam condensers: General knowledge of condensers, where, how and why
they are used. General care and upkeep of condenser auxiliaries.

15: questions 236,237; 19: questions 304,316,322,342;

30: p.505-524, 539-551

Steam plant accessories: Back pressure valves, non-return valves, throttle
valves, expansion joints, feed water regulators, steam separators, sight feed
lubricators, steam traps, reducing valves, sprinkler systems, function, location,
operation and care.

1: questions 62,63; 15: question 36; 19: questions 61, 62, 63, 75, 76, 96, 107,
428, 429, 430; 26: p.49-83; 27: p.67-89; 30: p.237-243, 256-273, 557-602

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.
5: p.1-21; 15: questions 101, 114, 217; 31: p.641-799

Operation and maintenance of controls: Basics.
19: questions 77,78,79

26: p.118-136; 27: p.137-152;

30: p.273-280

Air pollution and ecology: Basics.
15: questions 169,193; 27: p.162; 30: p.603-633

Plant safety.
15: question 196; 19: question 499; 26: p.191-199; 27: p.192-196



USACERL IR FE-95/03 67
Test Number and Title Status % Last Taken
PRETEST N - = ]
1101 Water Glass P 100 «08 Jun 93
#1102 Water Column P 100 08 Jun 93
1103 Safety Valves N - -
1104 Steam Gauges and Siphons N = -
*1105 Feed water, piping and valves P 100 06 Dec 93
1106 Blowdown valves, piping and tanks N - -
1107 Fusible plug N - -
1108 Boiler Stays N = -
#1109 Common types of boilers - Firetube and Watertube P 83 06 Dec 93
1110 Dangerous Boiler conditions F O 30 Aug 93
* = test locked, see your P = Passed N = Needed
, Supervisor for access. F = Failed Y= Tested Out
@ = Tests Imported
ESC to previous menu.

Figure H2, Sample test manager screen.



68 USACERL IR FE-95/03

Appendix I: CHPTUTOR Draft Proposal

RESEARCH PROPOSAL TITLE: Central Heating Plant Computer Guided Tutoring
System (CHPTUTOR) - System Requirements, Structure and Development Plan.

1. STATEMENT OF PROBLEM: The variety of equipment found in typical
Department of Defense (DOD) central energy plants and the complexity of the overall
operation and maintenance of these plants demands that the operators be highly
qualified personnel. In order to increase the safety and reduce the energy and
environmental cost of operating DOD central energy plants, a DOD wide operator
training and certification program needs to be developed and implemented. Industry
has recognized the need for standardizing training and certification of central heating
personnel for over 20 years with the establishment of the National Institute for the
Uniform Licensing of Power Engineers (NIULPE). Development of a mechanism to
take advantage of current DOD and industry training resources to guide the operator's
study efforts would greatly assist in meeting the requirement of operator training
certification. There is also a professional development requirement for many DOD
operators to complete curriculum that partially fulfills accepted operator certification
standards. It is highly desirable that any operator certification training program
complement current DOD study programs instead of compete with them.

2. REFERENCE: The tri-services working group meeting on the Certification and
Training of Central Heating Plant Operators held at Fort Belvoir, VA on 19-20 May
1992 has identified a need for training systems for central heating plant operators.
The working group expressed an interest in utilizing existing systems and standards
to meet this training need. The U.S. Air Force CERTEST System was singled out as
being a good product that could be modified into a tutoring tool.

3. OBJECTIVE OF PROJECT: The final product will be a computer based tutoring
system to prepare central heating plant operators and supervisors for certification.
The system will generate study questions for each curriculum subject necessary for a
particular class of certification. The design of the question bank must have the
flexibility to be addressed by the NIULPE curriculum and at least two other similar
training curriculums such as USAF Career Development Courses (CDC) or US Navy
Personnel Qualification System (PQS). The ability to track progress in similar



26

USACERL IR FE-95/03

USACERL recommends that the NIULPE examination standard tentatively be
used as a qualification standard for operators of DOD central heating plants.
However, full adoption of the NIULPE standard should be delayed until it is clear
that the USEPA standard will not disqualify the use of the NIULPE certification
to meet the intent of the CAAA 1990. Since the purpose of the NIULPE is to
establish a uniform procedure to measure the knowledge of operators across a
variety of facilities, it seems reasonable that DOD installation boiler operators
should be able to meet the NIULPE standard. Additionally, a NIULPE certifica-
tion or a similar USEPA standard may start to be a federal and state requirement
due to the CAAA 1990 mandate to improve air quality. Furthermore, the DOD
should continue work with the USEPA to ensure DOD training and certification
mechanisms are in agreement with the forthcoming USEPA standard.

It is recommended that all operators be required to have a fourth class license (by
examination) as a minimum. This training is currently available through the U.S.
Army Center for Public Works (USACPW), which, based on the recommendations
of the DOD study group, has put a contract in place to provide NIULPE 4th class
training and certification. Higher classes of licenses may be required for operators
of large or more complex plants (Appendix J). Additionally, all operators should
be required to fulfill some sort of recertification every 8 to 5 years to ensure
proficiency is maintained. The recertification could be met with a variety of
mechanisms, e.g., retaking a certification exam, successful completion of a course,
or successful completion of a computer-based test. During the implementation
period current operators should be given a generous amount of time (12 to 24
months) and multiple opportunities (four to six attempts) to pass the exam.
However, discussions with operators and supervisors in industry suggest that
there should not be grandfathering of current employees as this will undermine
the validity of the certification. Although the scope of this pilot program was for
operators only, it is recommended the NIULPE certification also be the standard
for supervisory and plant engineering personnel as well.



78

USACERL IR FE-95/03

Chief Engineer

Criterion Qualification

Education required High school, technical school, plant and management experi-
ence

Experience required 10 years

Examination required Oral, written, practical

Minimum time in previous grade 4 years

Maximum engine (prime mover) horsepower requir- | Unlimited

ing licensed power engineer (unsupervised)

Maximum boiler horsepower requiring licensed Unlimited

power engineer (unsupervised)

Refrigeration license (unsupervised) Unlimited

Examining Engineer

Criterion Qualification

Education required Bachelor's degree or equivalent

Experience required _ 12 years

Prerequisite _ Chief Engineer's license

Examination required Written

Technical instructor

Criterion Qualification

Education required Bachelor's degree or equivalent

Experience required 12 years

Prerequisite . Chief Engineer's license

Examination required Written



USACERL IR FE-95/03

the approach for a pilot program, the primary strategy of which was to use
existing industry accepted standards and products to meet the assessed training
and certification needs of DOD boiler operators. The Office of Personnel
Management (OPM) and several DOD personnel offices were contacted to
investigate the mechanisms for implementing a boiler operator certification
program.

A sample training course was designed and given at various DOD installations.
Course effectiveness was evaluated by administering and comparing the results
from pre- and post-tests, and from a a National Institute for the Uniform
Licensing of Power Engineers (NIULPE) standard examination. It was found that
the students showed marked improvement at the end of the pilot program.

The study recommended that the NIULPE examination standard tentatively be
used as a qualification standard for operators of DOD central heating plants until
it is clear that the USEPA standard will not disqualify the use of the NIULPE
certification to meet the intent of the CAAA 1990. The study also recommended
that all operators of DOD central heating plants be minimally required to have a
NIULPE Fourth Class Power Engineer license (by examination). This training is
currently available through the U.S. Army Center for Public Works (USACPW),
which, based on the recommendations of the DOD study group, has put a contract
in place to provide NIULPE 4th class training and certification. The study also
recommends specific training tools, including a continuing education program and
study materials that can help operators meet and maintain the recommended job
qualifications. Materials include currently available textbook and library
materials, videotapes, and workshops, as well as a proposed interactive, computer-
based training/testing program.

aaa NO
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2 USACERL IR FE-95/03

Executive Summary

The variety of equipment found in Department of Defense (DOD) central energy
plants (CEPs) and the complexity of these plants demands that CEP operators be
highly qualified personnel. Given the serious danger posed by improperly operated
boilers, similar operations in the private sector have long maintained processes to
establish credentials for their employees. The 1990 Clean Air Act Amendments
(CAAA; Public Law [PL] 101-549, 104 stat 2399) also recognize the importance of
trained and certified fuel plant operators toward improving air quality. As a result
of the CAAA 1990, the U.S. Environmental Protection Agency (USEPA) may
eventually require all operators of boilers with capacities greater than 10 million
BTU per hour (298 Boiler HP) to be trained and certified. The U.S. Environmental
Protection Agency (USEPA) has been tasked by the CAAA 1990 to develop model
training and certification programs for the operators of high-capacity fossil fuel
plants, which may eventually be applied to DOD installations.

The DOD operates nearly 100 installations in 12 jurisdictions that currently have
boiler operator licensing requirements in the interest of public safety. Since it is
one of the largest operators of CEPs in the United States, it is in the DOD’s
interest to minimize the impact of operating these plants on the environment, both
locally and nationally. The downsizing of the DOD and accompanying reduction
in available operating resources in both personnel and money has given the DOD
an interest in proactively working to meet the intent of the CAAA and to help the
USEPA develop a model training and certification standard. Such an effort would
further prepare the DOD to operate its plants with fewer personnel and lower fuel
costs to free resources for higher priority programs.

A DOD-wide training and certification program for CEP operators needs to be
developed and implemented to increase the safety and reduce the energy and
environmental cost of operating central energy plants, and to meet the CAAA 1990
requirements. This study examined the training needs of central energy plant
operators at DOD installations to identify the resources required to meet those
needs and to assess their effectiveness in the field.

A committee was formed to develop a strategy to implement boiler operator
training and certification standards in the DOD. This working group formulated
the approach for a pilot program, the primary strategy of which was to use existing


USACERL IR FE-95/03

15

was similar in content to the pre-test. Table 2 summarizes the results of the

post-test.

Table 2. Post-test results.

Parameters ' Results

Number of operators 127 (2 operators on leave, 3 supervisors unavailable)
Mean Score 83.3

Standard Deviation (the middle 68%) 12.7

Median Score 86

High Score 100

Low Score 40

NIULPE 4th Class Boiler Operator Examination

At the end of the course an independent examiner administered the NIULPE
Fourth Class Operator Examination. The exam consisted of 50 multiple choice
questions worth two points each. The NIULPE examination frequently appeared
more difficult for the operators than the pre-tests or post-tests. Table 3
summarizes the results of the NIULPE examination.

Table 3. NIULPE examination results.

Parameters

Number of operators

Mean Score

Standard Deviation (middle 68%)
Median Score

High Score

Low Score

Passing Rate

Result

123 (2 operators on leave, 1 operator unavailable, 2

| operators took 3rd class exam, 3 operators took 1st

class exam, 1 operator took chief's exam)
73.4

10.7

74

94

38

82% (105 of 123, including (2) 3rd class passes and
(1) 1st class pass)

Another contractor-operated facility tested their operators without the benefit of
a training course. Only 4 of 18 operators (31 percent) were able to pass the
NIULPE Fourth Class certification. Those scores are not included in the program
statistical summary since the examinees were not able to attend a training course.



USACERL IR FE-95/03

Contents

Executive Summary

Foreword ..... 00... ec cc cent eeeee
1 Introduction 0.0.6.6... cece eee eens
Background
Objective
Approach

5

Acronyms and Abbreviations

Appendix A: Clean Air Act Amendments Section 305

Mode of Technology Transfer

Program Description ............... 0c ee ee eeeeeee

NIULPE Standard
Skills Assessment
Resource Identification
Training Course
NAPE Library

Program Results .......... 0.0.00 cc cece

Course Performance

Operator Motivation and Knowledge
Plant Management and Operations
Assessment of Course Provider
Assessment of Examiners

Further Work ...... 00... c cece eee eee

Standard Boiler Operator Training Course
DOD Boiler Operators Study Book
Computer-Based Tutor

Regulation Issues

Design a Continuing Education Program

Conclusions and Recommendations ................-



Chief of Engineers,
‘ATTN: CEHEC-IMLH (2)
ATIN: CEHEC-IMLP (2)
ATTN: CECG
ATTN: CECC-P
ATIN: CECW
ATTN: CECW-O
ATTN: CECW.P
ATTN: CECW-PR
ATTN: CEMP
ATTN: CEMP-E
ATTN: CEMP.C
ATTN: CEMP-M
ATTN: CEMP-R
ATIN: CERD-C
ATTN: CERD-ZA
ATTN: CERD-L
ATTN: CERD-M
ATTN: CERM
ATTN: DAENZC
ATTN: DAIM-FDP-U

CECPW 22810-3862
ATTN: CECPW.E
ATTN: CECPW-EM
ATIN: CECPW-FT
ATIN: CECPW.ZC
ATTN: DET Ih 79906

US Army Engr Distct
ATTN: Library (40)

Us Army Engr Division
ATIN: Library (12),

US Army Europe
ATTN: AEAEN-EH 09014
ATIN: AEAEN-ODCS 09014

23th Area Suppor Group
ATTN: AERAS-FA 00054
100th Support Group
ATTN: AETT-EN-OPW 09114
222d Base Battalon
ATTN: AETV-BHR-E 09098
295th Base Suppor Battalion
ATTN: Unit 28614 Ansbach 09177
203d Base Support Battalion
ATTN: AEUSG-MA-AST-WO-E 09086
409th Support Battaion (Base)
ATTN: AETTG-DPW 09114
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ATTN: Unit 31401
Frankturt Base Support Battalion
ATTN: Unit 25727 09242
CTC Hohentels 09173
‘ATTN: AETTH-DPW
Mainz Germany 09185,
ATTN: BSB-MZ-E
2st Support Command
ATIN: DPW (2)
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ATTN: AEBAEH 08295
ATIN: AEBA-EN 08235
SETAE
ATTN: AESE-EN-D 09613
ATTN: AESE-EN 09690
Supreme Alied Command
ATTN: ACSGEB 09703
ATTN: SHINB/ENGR 09705

INScOM
ATTN: IALOG-1 22060
‘ATTN: IAV-DPW 22188

USA TACOM 48307-5000,
ATTN: AMSTA-XE

Defense Distribution Region East
ATTN: DDRE-Wi 17070

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ATTN: AFZA-DPW-EE

This publication was reproduced on recycled paper.

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ATIN: AFZC-FE

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ATTN: AMCENF

Installations: (19)

FORSCOM
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ATTN: FCEN
Installations: (23)

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ATIN: APVADE 99505
ATTN: APVR.WF-DE 99703

‘TRADOC

Font Monroe 23651
ATIN: ATBO-GFE
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Instalations: (20)

Fort Belvoir 22060
ATIN: CETEGNT
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ATTN: Water Resources Support Cir
ATTN: Australian Liaison Office

USA Natick RD8E Center 01760
ATTN: STRNC-OT
ATIN: DRONA

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ATTN: SLOMT-DPW 02172

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ATTN: Intastructure Branch LANDA

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ATTN: DRXMR-AF
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CEWES 99180
ATIN: Library

CECAL 03755
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USA AMCOM
ATIN: Facies Engr 21719
ATTN: AMSMC-EH 61299
ATTN: Facies Engr (3) 85613

USAARMC 40121
ATTN: ATZIC-EHA

itary Trae Mgmt Command
ATTN: MTEA-GB-EHP 07002
ATTN: MT-LOF 20315
ATTN: MTE-SU-FE 26461
ATTN: MTW-IE 94626

Fort Leonard Wood 65473,
ATIN: ATSE-DAC-LB (3)
ATIN: ATZATE-SW
ATIN: ATSE-CFLO
ATTN: ATSE-DAC-FL.

itary Dist of WASH
Fort McNair
‘ATTN: ANEN 20319

USA Engr Activity, Capital Aroa
ATTN: Library 22211

US Army ARDEC 07806
TIN: SMCARISE

Engr Socioties Library
ATTN: Acquisiions. 10017,

Defense Nuclear Agency
‘ATTN: NADS 20305

Defense Logistics Agency
ATTN. DLAWI 22904

Walter Reed Army Medical Ctr 20307

National Guard Bureau 20310
ATTN: NGB-ARI

Us Miltary Academy 10096
ATI: MAEN-A
ATIN: Facities Engineer
ATTN: Geography & Enir Engrg

Naval Facies Engr Command
ATTN: Facities Engr Command (8)
ATTN: Division Ofces (11)
ATIN: Public Works Center (8)
ATTN: Naval Constr Battaion Cr 98043
ATTN: Naval Fcities Engr Service Center 99043-4328
ATTN: Naval Facies Engr Ser Contor (Code 241)

‘th US Army Korea
ATIN: OPW (12)

USA Japan (USARJ)

ATIN: APAMEN-ES 96943
ATTN: HONSHU 96343
ATIN: DPW-Okinawa 96376

‘416th Engineer Command 60623
ATTN: Gibson USAR Cir

Us Army HSC
Fort Sam Houston 78234
ATIN: HSLO-F
Fitzsimons Amy Medical Cr
ATTN: HSHG-DPW 80045

‘Tyndall AFB 32403
ATIN: HOAFCESA Program Ofc
ATTN: Engrg & Sive Lab

USA TSARCOM 63120
ATIN: STSAS-F

‘American Public Works Assoc. 64104-1806

Us Army Envr Hygiene Agency
ATTN: HSHB-ME 21010,

US Gov' Printing Office 20401
ATTN: Rec Sec/Deposit Sec (2)

Natl Insitute of Standards & Tech
ATTN: Library 20899

‘Submarine Base, New London
ATTN: Code 860

Norfok Naval Staton 23511
ATTN; Code 670

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ATTN; Code 6880

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Defense Tech Info Canter 22904
ATTN: DTIG-FAB (2)

3 U.S. GOVERNMENT PRINTING OFFICE: 19¢4—3510-S/00071



USACERL IR FE-95/03

Topic - Tape Number PIN a
Algebra and Formulas: : : PT 802729 DN
Algebra and Graphs . . : P-8 —_ : 802730 DN ;
Fundamentals of Math Applications Pg 802731 DN
Using Formulas — , P-10 802732 DN -
Graphs, Charts, and Tables ; P-11 802733 | DN
Power Generation Problems ; P-12 802734 DN
Energy Conversion 7 | P4300 802735 DN
Properties and Fluid Flow 7 : P-14 : 802736 DN
Pressure : _ a : P+15 _ 802737 ON
Temperature and Heat _ - P-16 802738 DN
Water/Steam Properties P-17 802739 DN |
Applications P-18 802740 DN
Steam Tables P-19 802741 DN
Plant Performance P-20 802742 DN
Fluid Flow, Piping, and Piping Auxiliaries P-21 802743 DN
Pumps and Drives P-22 802744 DN
Compressors and Fans : P-23 802745 DN
Operation of Plant Auxiliaries - P-24 802746 DN
Reading System Diagrams P-25 802747 DN
Steam Systems P-26 802748 ON
Condenser, Circulation Water, and Fire Systems P-27 802749 DN
Condensate and Feedwater Systems P-28 802750 DN
Fundamentals of Electricity 1 P-29 802751 DN
Fundamentals of Electricity 2 : P-30 . 802752 ‘DN
Batteries, Generators, and Motors : P-31 802753 DN
Transformers and Control Mechanisms P-32 802754 DN
Principles of Instrumentation P-33 802755 DN
Pressure and Flow Measurement . P-34 802756 DN
Level and Temperature Measurement : P-35 ; 802757 DN
Reading Instrumentation of Pald's : P-36 802758 DN
Chemistry Concepts : P37 802759 DN
Water Chemistry Fundamentals P-38 802760 DN



83

|
| USACERL IR FE-95/03

Topic

Measurement Tools 2

Power Tools

Resurfacing Techniques
Gauge Glass Maintenance
Heating Exchangers 1

Heating Exchangers 2
Maintenance Practices

Print Reading and Use

Pipe and Pipe Fitting

Safety Valves 1

Safety Valves 2

Valve Maintenance 1

Valve Maintenance 2

Piping Auxiliaries

Steam Traps

Thermal Insulation

Fire Safety -

Hazardous Substances
Personal Safety a.
Respiratory Protection :
Centrifugal Pumps 1

Centrifugal Pumps 2 :
Positive Displacement Pumps 1
Positive Displacement Pumps 2
Couplings and Shaft Alignment
Mathematics 1

Mathematics 1

Safety in Instrumentation Maintenance
Pressure and Pressure Measurement
Pressure Gauges and Calibration 1

Pressure Gauges and Calibration 1

Force Weight and Motion Measurement

Tape Number
M-20
M-21
M-22
M-23
M-24
M-25
M-26
M-27
M-28

M28
M-30
M-31
M-32
M-33
M-34
M-35
M-36
M-37
M-38
M-39
M-40
M-41
M-42
M-43
M-44

12
1-3
4
15

7

PIN
802822
802823
802824
802825
802826
802827
802828
802829
802830

802831

802832

802833

802834
802835
802836
802837
802838
802839
802840
802841
802842
802843
802844
802845
802846
802847
802848
802849
802850
802851
802852
802853

goog
22 2



USACERL IR FE-95/03

schedule in Appendix Eis constructed to provide this balance and to afford the
operators opportunity to attack the more difficult topics earlier in the course. The
amount of time devoted to the various topics was based on USACERL observation
of operator performance on the exam and operator feedback from interviews.

Course Materials

Although there are a variety of industrial courses and study guides, the instructor
should modify his presentation to use the NAPE materials. The instructor should
reference his presentation to specific sections in NAPE-recommended reading
materials. This will reinforce the self-study efforts of the operators before and
after the course. Additionally, for each learning objective the instructor covers, the
students should be informed of the precise NIULPE topic under review to assist the
self-study process.

Instructor Credentials

The instructor should have extensive experience as a heating or power production
operator or supervisor to quickly gain the respect of the seasoned operators. The
instructor must be a certified NIULPE Technical Instructor and a licensed NIULPE
Chief Engineer to ensure that quality courses are conducted. Additionally, the
instructor must be willing to give references from previous clients to help establish
the instructors effectiveness before using his services.

At the completion of the course, the examination must be administered by a
separate interest from the instructing agency or company. Although some industry
instructors are also licensed as examiners, this separation of tasks is healthy to
reduce the tendency of an instructor to teach the examination instead of the
curriculum.

DOD Boiler Operators Study Book

USACERL has reviewed some of the publications in the NAPE library (Appendix
B) and found them to be useful. With the permission of NAPE, USACERL
duplicated and bound six of the NAPE publications to be used as a pre-course
study book. USACERL constructed a study guide (Appendix G) to direct the
operator to specific locations in the study book that address NIULPE curriculum
topics for fourth class operators. Additionally, within the NAPE library, there are
several home study courses. It may be fruitful to develop an update to one of
these courses with the permission and cooperation of NAPE. This book could be
a single source to help the operator prepare for the certification exam. Another



US Army Corps
of Engineers

Construction Engineering
Laboratories

Research

USACERL Interim Report FE-95/03
November 1994

The Department of Defense Central Heating
Plant Operator Training and Certification

Program: An Overview

by
Michael K. Brewer and Ralph E. Moshage

The variety of equipment found in Department of
Defense (DOD) central energy plants (CEPs) and the
complexity of these plants demands that CEP operators
be highly qualified personnel. Given the serious danger
posed by improperly operated boilers, similar opera-
tions in the private sector have long maintained
processes to establish credentials for their employees.
The 1990 Clean Air Act Amendments (CAAA 1990)
also recognize the importance of trained and certified
fuel plant operators toward improving air quality. As a
result of CAAA 1990, the U.S. Environmental Protection
Agency (USEPA) will eventually require all operators of
boilers with capacities greater than 10 million BTU per
hour (298 Boiler HP) to be trained and certified.

A DOD-wide training and certification program for CEP
operators needs to be developed and implemented to
increase the safety and reduce the energy and envi-
ronmental cost of operating central energy plants, and
to meet the CAAA 1990 requirements. This study
examined the training needs of central energy plant
operators at DOD installations to identify the resources
required to meet those needs and to assess their
effectiveness in the field.

Approved for public release; distribution is unlimited.

ot



USACERL IR FE-95/03

Tople -

Liquid Level Measurement 1

Liquid Level Measurement 2

Fluid Flow Measurement 1

Fluid Flow Measurement 2

Temperature and Temperature Measurement 1
Temperature and Temperature Measurement 2
Actuators
Recorders -
Basic Process Control 1
Basic Process Control 2
Basic Control Loops _
| Instrumentation Troubleshooting and Repair
Basic Electronics a

Basic Electronics 2

Power Supplies

Transistor Principles
Transistor Amplifiers : :
Transistor Oscillators
Specialized Electronic Devices
Operational Amplifiers 1
Operational Amplifiers 2 -
Vacuum Tubes and Circuits

Using Electronic Test Equipment. 1
Using Electronic Test Equipment. 2
Using Electronic Test Equipment. 3
Cable and Wire Terminations
Circuit Board Repair

Electronic Control Systems 1
Electronic Control Systems 2
Electronic Control Systems 3
Electronic Control Diagrams

Basic Pneumatic Systems and Diagrams

Tape Number
- 1-8
1-9
1-10

PIN ;
802854 | DN
802855 | DN
902856 = DN
902857 DN
802858 | DN
802859 | DN
802860 | DN
802861 DN
802862 | DN
802863 | DN
902864 | DN
02865 DN
gozess =| ‘DN
802867 | ‘DN
gozs68 | DN
802869 | DN
802870 DN
802871 DN
802872 | DN
802873 | DN
0274 | DN
802875 | DN
802876 | DN
802877 | DN
02878 | DN
02879 | DN
02880 =| «~DN
802881 DN
02882 | ~DN
0283 | «DN
gozes4 =: DN
02885 «DN



USACERL IR FE-95/03

24.

is a term used to describe the total energy contained in

steam.

25.

27.

29.

temperature
pressure
entropy
enthalpy

Be op

In room air conditioners, air is cooled as it is blown across the
a. condenser
b. compressor
c. expansion valve
d. evaporator

. A hermetic compressor in a chiller is cooled by

a. compression
the refrigerant
evaporation
water

coil

oRes

The heat used to change a liquid to a gas or vapor is called
a. the latent heat of adsorption

the latent heat of absorption

the latent heat of vaporization

the latent heat of fusion

the latent heat of liquids

eae

. Electricity consumption is measured and sold by

a. the demand

kilovolt ampere (KVA)
kilowatt hour (KWH)
kilowatt (KW)
kilovolt (KV)

mee

Pneumatic control systems use to convey control signals.
electricity

oil

air

water

Be op



USACERL IR FE-95/03

Environmental Impact, Energy Efficiency, and Safety

Given the complex nature of boiler systems and the serious danger posed by
improperly operated boilers, the heating and power industry in the private sector
has long maintained a licensing or certification process to establish minimum
credentials for their employees. Additionally, the 1990 Clean Air Act Amendments
(Public Law [PL] 101-549, 104 stat 2399, hereafter referred to as CAAA 1990, and
included in Appendix A to this report) recognize the importance of properly trained
and certified operators of high-capacity fossil fuel plant in improving air quality.
The U.S. Environmental Protection Agency (USEPA) has been tasked by the CAAA
1990 to develop model training and certification programs for the operators of high-
capacity fossil fuel plants, which may eventually be applied to DOD installations.
Much of the federal environmental law enforcement has been delegated to the state
environmental agencies. Currently certain positions, such as waste treatment plant
operators, require state licensing of federal employees where the state is enforcing

federal mandates.

The DOD operates nearly 100 installations in 12 jurisdictions that currently have
boiler operator licensing requirements in the interest of public safety. Although the
federal government has historically held itself immune from many state licensing
programs, federal mandates to the state on environmental issues could override
that immunity. Additionally, certification has been used in several federal agencies
to establish minimum credentials for certain occupations.

Since 1987, the Army, Navy, and Air Force have investigated implementing boiler
operator training and certification mechanisms. These investigations have
identified the benefits and liabilities of at least three different strategies to
implement a training and certification program. The first strategy was to simply
use an available state or municipal license. This option was ruled out since it
would not give the DOD uniform or fair testing requirements between installations
and/or between states. A second option would be to establish a government
certification and testing board. This would create a uniform standard, but at high
startup and operation costs. The third option was to use the existing National
Institute for the Uniform Licensing of Power Engineers (NIULPE) standard,
already the standard in the 28 states that have NIULPE chapters. This
alternative is in agreement with the U.S. Navy initiative on boiler certification,
which indicated that using a nationally recognized, third-party licensing standard
seemed to be more advantageous than establishing a new U.S. Navy certification
infrastructure or attempting to comply with each jurisdiction’s particular standard.

Circumstances have made the development of a qualification standard a pressing
issue. USACERL researchers met with representatives from the Naval Facilities



USACERL IR FE-95/03

1 Introduction

Background
Legal Requirements

The variety of equipment found in typical Department of Defense (DOD) central
energy plants (CEPs) and the complexity of the overall operation and maintenance
of these plants demands that plant operators be highly qualified personnel. Army
Regulation (AR) 420-15 requires that “all utility plant supervisors (e.g., foreman),
[and] operators . . . will be properly certified.” In addition to requiring operator
certification, the regulation stipulates that mechanisms be made available to give
personnel the opportunity to acquire the required skills, specifically that “formal
and/or informal training programs will be established for those employees
requiring additional training to upgrade their skills, to qualify them for
certification, and to provide for their career development.” Additionally, AR 420-
15 encourages that “Advantage should be taken of existing training programs
within the Department of Defense (DOD), Department of the Army, industry, and
Federal or State Governmental agencies.” Specific details for carrying out these
training and certification requirements are the responsibility of the major
commands of each service branch.

The Air Force has recognized this need for standards in Air Force Manual 85-12
Volume 1 (AFM 85-12 Vol. 1), which states that, “It is highly desirable that plant
supervisors and operators be licensed; it is mandatory that they be qualified by
training and experience to operate and maintain equipment properly and
efficiently. Personnel should be encouraged to obtain licenses and to participate
in local training schools, Air Force training programs and self-study.” Addition-
ally, AFM 85-12 Vol. 1 paragraph 88 and Air Force Regulation 91-7 (AFR 91-7)
stipulates that there must be a training and certification mechanism managed by
the base engineer to fulfill the requirement that only qualified personnel operate
plant equipment.

. Army Regulation (AR) 420-15, Certification of Utility Plant Operators and Personnel Performing Inspection and
Testing of Vertical Lift Devices (Headquarters, U.S. Army Corps of Engineers [HQUSACE], 03 June 1975).



USACERL IR FE-95/03

57

Appendix F: NIULPE Fourth Class Power
Engineer Curriculum

A Curriculum to Cover the Basic Fundamentals shall include:

10.

11.

12.
13.

14,

15.

Water glass: Placement, function, how held in place, length, maintenance, valves
needed, replacement, how and when tested.

Water column: Placement, function, how held in place, length, care, what could
affect its efficiency, maintenance, valves and cocks needed, how and when tested.
Safety valve and rupture discs: Placement, function, care, maintenance, how and
when tested, description, potential failures, adjustment for pressure.

Steam gauge and siphon: Placement, principle, function, care, maintenance,
potential failures, how and when tested.

Feed water, piping and valves: Location, care, maintenance, potential failures.
Reason for valves on piping, how ‘ept in good condition. Reason for internal pipe.
Blow down valves, piping and tank: Location, purpose, potential failures, care.
Fusible plug: Where placed, purpose, how kept in good condition, possible
failures, description. Installation, when renewed.

Stays: Placement, purpose, types, description, care advantages of various types,
potential failures.

Two common types of boilers-fire tube and water tube: Description and
characteristics. Qualities of good boiler.

Dangerous conditions: When a boiler should not be operated. Causes of boilers
being burned or exploded.

Corrosion, pitting, priming and foaming, bulging, bagging: Meaning of each,
where found and how created, dangers and remedies.

Scale and mud: Where found, cause, prevention, effect, dangers, removal.

Feed water treatment: Meaning, purpose, how applied and controlled, dangers
of over-treatment and under-treatment.

Feed Water heaters: Types, purpose, advantages, methods of heating feed water,
applications, potential failures.

Mathematics: A knowledge sufficient to solve any simple problem involving
division and multiplication.



USACERL IR FE-95/03

The primary function of boiler blowdown is to prevent

a. low water levels

b. excess water levels
accumulation of chemicals
excess pressure
accumulation of sludge

- ae

The first duty of an engineer coming on duty is
a. check boiler temperature

check boiler water level

check boiler pressure

check for boiler leaks

check for boiler safety settings

eos

2

Heat transfer methods are

radiation, reflection, infiltration
convection, radiation, lumens

as defined in ASHRAE 63-1989
radiation, convection, conduction
combustion, convection, radiation

ope oe

Boiler feed water control is used
a. to control pressure

to control temperature

to control safety valves

to control water level

to control chemistry

ope

I can continue to run my boiler
with a tube failure

with a steam drum leak
with a safety valve blowing
with a gauge glass broken
with refractory failure

pao oe


USACERL IR FE-95/03

81

Tope
Elementary Water Treatments
Water Chemistry Applications
Fuel and Combustion _

Coal Handling Equipment

Oil and Gas Handling Equipment
and Flame Characteristics

Ash Handling Equipment

Boiler Fundamentals

Startup and Shutdown Procedures

Normal Operation and Boiler Efficiency :
Abnormal Conditions and Emergency Procedures
Boiler Water Treatment

Raw Water Treatment

lon Exchange

Cooling Water Treatment

Turbine Construction and

Principles of Operation :
Turbine Valves and Support Systems
Turbine Control, Instrumentation,

and Protection =

Turbine Operation

Environment _

Water Pollution

Air Pollution: Particulate

Air Pollution: Gas

Sensing, Measuring, and Controlling Elements
Controllers and Final Control Elements
Types of Control

Drum Level and Combustion Control
Generator Principles

AC Power :

Generator Auxiliary Systems

Generator Operation

Tape Number
P-39
P-40
P-41
P-42

P-43
P-44
P-45
P-46
P.47
P-48
P-49
P-50
P54
P-52

P53
P-54

P-55
P56
P-57
P-58
P-59
P.60
P-61
P-62
P-63
P-64
P65
P-66
P-67
P-68

_ PIN
802761
802762
802763
802764

802765
802766
802767
802768
802769
802770
goat
802772
802773
802774

802775
802776

802777

802778
802779
802780
802781
802782
802783
802784
802785
802786
802787
802788
802789
802790

DN
DN
DN
DN

DN
DN
DON
DN

DN
DN

DN
DN
DN
DN

DN
DN

DN
DN
DN
DN

DN

DN
DN
DN
DN
DN
DN
DN
DN
DN



28 USACERL IR FE-95/03

Appendix A: Clean Air Act Amendments
Section 305

P.L. 32-649 LAWS OF 10ist CONG.—2nd SESS. Nov. 15
days of the submission, and if a plan is disapproved, the
Administrator shall state the reasons for disapproval in writing.
Any State may modify and resubmit a plan which has been
disapproved by the Administrator.

“(3) FEDERAL PLAN.—The Administrator shall develop, imple-
ment and enforce a plan for existing solid waste incineration
units within any category located in any State which has not
submitted an approvable plan under this subsection with
respect to units in such category within 2 years after the date
on which the Administrator promulgated the relevant guide-
lines. Such plan shall assure that each unit subject to the plan
is in compliance with all provisions of the guidelines not liter
than 5 years after the date the relevant guidelines are promul-

gated.

Regulations “(c) Monrrortnc.—The Administrator shall, as part of each
performance standard promulgated pursuant to subsection (a) and
section 111, promulgate regulations requiring the owner or operator
of each solid waste incineration unit—

“(1) to monitor emissions from the unit at the point at which
such émissions are emitted into the ambient air (or within the
stack, combustion chamber or pollution control equipment, as
appropriate) and at such other points as necessary to protect
public health and the environment;

(2) to monitor such other parameters relating to the oper-
ation of the unit and its pollution control technology as the
Administrator determines are appropriate; and

“(2) to report the results of such monitoring.

Such regulations shall contain provisions regarding the frequency of
monitoring, test methods and procedures validated on solid waste
incineration units, and the form and frequency of reports containing
the results of monitoring and shall require that any monitorin;
reports or test results indicating an exceedance of any standar
under this section shall be reported separately and in a manner that
facilitates review for purposes of enforcement actions. Such regula-
tions shall require that copies of the results of such monitoring be
maintained on file at the facility concerned and that copies shall be
made available for inspection and copying by interested members of
the public during business hours. .

“(d) Operator TRAINING.—Not later than 24 months after the
enactment of the Clean Air Act Amendments of 1990, the Adminis-
trator shall develop and promote a model State program for the
training and certification of solid waste incineration unit operators
and high-capacity fossil fuel fired plant operators. The Adminis-
trator may authorize any State to implement a model program for
the training of solid waste incineration unit operators and high-
capacity fossil fuel fired plant operators, if the State has adopted a
program which is at least as effective as the model program devel-
oped by the Administrator. Beginning on the date 36 months after
the date. on which performance standards and guidelines are
promulgated under subsection (a) and section 111 for any category of
solid waste incineration units it shall be unlawful to operate any
unit in‘the category unless each person with control over processes
affecting emissions from such unit has satisfactorily completed a
training program meeting the requirements established by the
Administrator under this subsection.

“(e) Permits.—Beginning (1) 36 months after the promulgation of
a performance standard under subsection (a) and section 111

104 STAT. 2580



USACERL IR FE-95/03

45

30. Electrical transformers

31.

382.

33.

34.

35.

a.

eases

provide metering methods
change voltage levels

add capacity

subtract capacity

redirect electrical services

Globe valves are used primarily as

a.

ae o

throttle valves
isolation valves
safety valves
relief valves

Both valves on a water glass must be open to provide

aoe

circulation of water

a true level indication

a good. vacuum

proper heating of the glass

Check valves are used to

a.

b.
c.
d

throttle flow

. relieve excessive pressure

allow flow in one direction only

. relieve excessive level

Sensible heat is heat that

a.

b.
c.
d.

can be measured with a thermometer

cannot be measured with a thermometer

is created by pipe friction only

is unrelated to heating and refrigeration plant operation

Freon is very suitable for use in refrigeration systems due to its

a.

b.
ce
d.

density

high temperature boiling point
low temperature boiling point
extremely low cost



USACERL IR FE-95/03 27

Acronyms and Abbreviations

AFR Air Force Regulations
AR Army Regulation
ASME American Society of Mechanical Engineers

CAAA 1990 Clean Air Act Amendments of 1990 of the 101st Congress
CECPW U.S. Army Center for Public Works, Fort Belvoir, VA
CERTEST USS. Air Force computer-based skills test

CheckMaster U.S. Air Force infrastructure equipment procedure checklist
computer program

DOD Department of Defense
NAPE National Association of Power Engineers
NFESC Naval Facilities Engineering Service Center Activity, Port

Hueneme, CA

NIULPE National Institute for the Uniform Licensing of Power Engineers
OPM Office of Personnel and Management
USACERL U.S. Army Construction Engineering Research Laboratories

USEPA U.S. Environmental Protection Agency



USACERL IR FE-95/03

24.

25.

26.

27.

28.

Steam non-return valve, expansion joints, heaters, steam separator,
sight feed lubricator, steam trap reducing valve, feed water regulator:
Function, use and location.

1: question 9; 19: questions 61,62,63,73,107,431,432,433,435;

22: p.15,28

25: Lesson 7 p.13-18; 27: p.31-32,37,77,81-84,93-94;

30: p.237-243,256-261,444,575,589-592

Refrigeration compressor, condenser, receiver, evaporator, purge,
expansion valve, charging, liquid, suction, discharge, cross-over
valves: Purpose, location , dangers, correct operating procedures.

8: p.4-28; 5: p.10-17;

15: questions 41,123,220; 16: Elem. questions 17,18; 31: p. 73-140

Air compressor: Dangers in operation, maintenance, correct operating
procedure.

15: question 174; 16: Inter. question 13;

19: questions 448,452,454,460,462,467,472,490,494,499

Electrical equipment: Fuses, cut outs, relays, switches, circuit breakers,
purposes and comparative applications. Dangerous conditions in operation of
a motor. Prevention of starting. Sizes of fuses. Carrying capacities of wires
for lighting circuits. Volt, ampere, watt, Ohm, D.C., A.C., electrical conductor,
electrical insulator: Meaning of these terms. Difference between electric
generator and motor. .

2: questions 1,3; 15: questions 22,49,71,127,135,185,196,235,254;

16: Elem. questions 1,25

23: Lessons 3-22; 29: p. 21-43

Steam engines: Types, setting valves, purpose of fly wheel, eccentric,
governor, cross head, lead, lap, angle of advance, valve travel and cutoff,
methods of lubrication and application to various parts, how started and how
shut down, maintenance and care.

16: Elem. questions 14,15; 19: questions 205,225,419,420; 22: p.22,23;

” 80: p.885-473


4 USACERL IR FE-95/03

Foreword

This study was conducted for the U.S. Army Center for Public Works (USACPW),
and Headquarters, U.S. Army Training and Doctrine Command (TRADOC), and
the Naval Facilities Engineering Service Center (NFESC) under Project 4A162-
784AT45, “Energy and Energy Conservation”; Work Unit EB-XK3, “Central
Energy Supply: Advanced Operations and Maintenance,” and Military Interde-
partmental Purchase Request (MIPR) No. E87420477 and N0002593MPO06M.
The technical monitors were Qaiser Toor, DAIM-FDF-U; Dennis Vevang,
CECPW-EM; Conrad Browe, HQ-TRADOC-ATBO-GFE; and A. Henry Studebaker,
NFESC Code 241.

The work was performed by the Energy and Utility Systems Division (FE) of the
Infrastructure Laboratory (FL), U.S. Army Construction Engineering Research
Laboratories (USACERL). Donald Fournier is Acting Chief, CECER-FE, and Dr.
David Joncich is Acting Chief, CECER-FL. The USACERL principal investigator
was Ralph E. Moshage. Special appreciation is expressed to the public works
staffs at Fort Eustis, VA, Fort Knox, KY, Fort Benning, GA, Fort Lee, VA,
Picatinney Arsenal, NJ, Norfolk Naval Station, VA, Camp Pendleton, CA, and
Puget Sound Naval Shipyard, Bremerton, WA for their participation in the pilot
programs. Thanks is owed to Qaiser Toor, SFIM-IS-FP-U, and Henry Studebaker,
NFESC, for their assistance and guidance throughout the project. The USACERL
technical editor was William J. Wolfe, Information Management Office.

LTC David J. Rehbein is Commander and Acting Director, USACERL, and Dr.
Michael J. O'Connor is Technical Director.


18 USACERL IR FE-95/03

Assessment of Course Provider
Instructor Knowledge and Motivation

Most of the instructors were interested and knowledgeable individuals. Those who
had extensive experience as boiler operators or boiler supervisors quickly
established credibility with the students. Additionally, some of the instructors
availed themselves to give individual instruction to those operators who needed
extra tutoring.

Course Content

Each instructor was allowed to design a syllabus and select materials for the
course. In general, most instructors distributed a single notebook or text to each
operator. At one installation, the instructor used three separate sets of notes for
his lectures. The syllabus formats generally followed the progression of the text
or notebook with the instructor using overhead projections or videos for supple-
mental information.

The curriculum strategy of using one main text or notebook was very useful to the
students. The use of a single, well-indexed book allowed the operators to study
on their own. Additionally, a text or notebook can provide a convenient study
resource as the operators pursue higher levels of qualification.

The curriculum structure needed more attention as presented at some installa-
tions. Some of the courses appeared to review at the expense of covering other
pertinent material. Although a greater amount of review seems to be warranted
for older students, it is important to cover all of the required knowledge areas.
Poor organization in the review effort resulted in the topics covered near the end
of the week sometimes being denied needed explanation. It would have been
profitable to spend more time discussing and reviewing electricity and refrigera-
tion cycles earlier in the week as evidenced by poor performance in the NIULPE
examination in those topics. Additionally, any future course should acknowledge
the DOD guidance and regulation on safe and efficient boiler operation.

Assessment of Examiners
The examiners did a good job administering the NIULPE examination and

explaining the significance of the NIULPE license. Many of the examiners
counseled each operator on completing the grading of the examination. The effort



USACERL IR FE-95/03
Topic . : Tape Number | PIN
Reading Electrical Diagrams | P-69 | 802791 | DN
- | | .

Three Phase Power | P-70 | 802792 DN
. | - :

Unit Transformers, Switchyards, | | i
and Substations i P-71 | 802793 | DN
Station Service Systems H P-72 f 802794 | DN
Fundamentals of Plant Protection \ P-73 | 802795 i DN
Electrical Protection | P-74 | 802796 | DN
Boiler and Turbine Protection | P-75 802797 DN

— ~ |

Logic Diagrams and Integrated Plant Protection I P-76 : 802798 =| DN

~ 2 4 H '
Gas Turbine Principles P-77 | g02799 | DN
Components of Gas Turbine Units | P-78 802800 | ON

a i - H . = |
Gas Turbine Operations and Availability P-79 | 802801 | DN

- ee | |
Power Generation Diesels { P-80 802802 | DN
Air Compressors 1 | MA | gozgos. «| s«DN

oe
Air Compressors 2 | M-2 | 802804 i DN

H

Basic Bearings M-3 802805 DN
Basic Lubrication | M4 | 80206 | (DN
Rolling Contact Bearings 1 M-5 | 802807 DN
Rolling Contact Bearings 2 - M-6 802808 DN
Sliding Surface Bearings 1 M-7 : 802809 7 DN
Sliding Surface Bearings 2 M-8 802810 DN
Boiler Maintenance M-9 - 802811 =| DN
Boiler Tube Repairs M-10 802812 DN
Boiler Inspection and Cleaning 1 M-11 802813 DN
Boiler Inspection and Cleaning 2 M-12 802814 DN
Refractory Maintenance M-13 802815 DN
Sootblower Maintenance M-14 802816 DN
Cutting Tools M-15 802817 DN
Gaskets, Packing, and Mechanical Seals M-16 802818 DN
Hand Tools 1 M-17 802819 DN
Hand Tools 2 . | M18 goze20 | DN
Measurement Tools 1 M-19 802821 DN



USACERL IR FE-95/03

Overall Program Time Budget:

Administration 7 | 2 hours
Lectures - | 24.5 hours
Tours ) 1 hour
Video Presentation Lhour —
Review | 8 hours 7
NIULPE testing 3.5 hours
Total | 40 hours

Below is a recomended program schedule. The schedule was based on using 4.5 days
to conduct a class and 0.5 days to administer a NIULPE examination. The amount of
time devoted to the various topics was based on our observation of operator perfor-
mance on the exam and operator feedback from interviews in previous pilot courses.
It is recommended some of the more difficult topics such as electricity and refrigeration
equipment be covered early in the course to afford the instructor opportunity to
conduct extra review or to allow operators time to study on their own if needed.

Sample Schedule:
Time | Monday Tuesday | Wednesday | Thursday Friday
8:00 Admin AC&R Comb/Poll Review Review
8:30 Pre-Test AC&R Comb/Poll Review Review
9:00 Pre-Test AC&R B. Controls Steam/Pipe Post-Test
9:30 Math AC&R B. Controls Ops/Maint Post-Test
10:00 | Math AC&R B. Controls Ops/Maint Review
10:30 | Math AC&R FeedW/Chem | Ops/Maint Review
11:00 | Elect B. Features | FeedW/Chem Ops/Maint Review
11:30 | Elect B. Features FeedW/Chem | Safety Review
12:00 | Lunch - Lunch _| Lunch | Lunch Lunch
13:00 | Review Review Review Review NIULPE —
13:30 | Elect | Tour — Video Video NIULPE
14:00 | Elect Tour Pump/Inj Safety NIULPE



79

| USACERL IR FE-95/03
|

Appendix K: NUS Tape Ordering Procedure

To order reproducible video tapes mentioned in this report, submit a Military
Interdepartmental Purchase Request (MIPR), DD Form 448. Ensure entries are
made in block 5 and block 16. In the description block indicate the tape
identification number (i.e., 802-723). Enter a POC and POC phone number in
block 8 to allow the Joint Visual Information Activity to clarify or correct requests.
The price for each 1/2-in. VHS format tape as of 16 May 94 is $6.00. Send MIPR’s
to:

USACVIC/JVIA

ATTN: ASQV-JVIA-T-AS

Bldg 3., Bay 3

11 Midway Road

Tobyhanna Army Depot, PA 18466-5102

POC: Debbie Whitaker, DSN: 795-7438, FAX 795-6106; COMM: 717-894-7438
FAX: 717-894-6106

Prices are subject to change based on costs of blank video tapes. These tapes are
available to DOD and DOD government-owned, contractor operated activities only.
DOD has been granted a license to reproduce unlimited copies of the video tapes
listed in this appendix.

Table’ K1. NUS Tapes

Topic Tape Number PIN
Functions of the Power Plant P+ 802723 DN
Boilers P-2 802724 DN
Turbine Fundamentals - P-3 802725 i DN
Plant Operation P-4 : 802726 7 DN
Number and Number Systems P65 | 802727 DN
Powers, Roots, and Measurements P+ 802728 DN



USACERL IR FE-95/03 85
Topic Tape Number PIN
Pneumatic Instrument Tubing : 1-40 802886 | DN
Pneumatic Control Equipment 1 a 802887 | DN
Pneumatic Control Equipment 2° 1-42 802888 DN
Pneumatic Control Equipment 3 1-43 802889 DN
Pneumatic Actuators and Positioners ; 44 802890 ON
Basic Pneumatic Control Systems 1-45 802891 DN
Multi-Element Pneumatic Controt Systems : 1-46 802892 DN
Troubleshooting Pneumatic Instrument Systems 1-47 802893 DN
Tuning Pneumatic Control System 1-48 802894 DN
Pneumatic Controllers 1-49 802895 DN
Basic Electricity Review E+ 802896 DN
DC Fundamental Review E-2 802897 DN
AC Fundamentals Review — E-3 802898 DN
Electromagnetic Induction Review E-4 802899 DN
Safety in Electrical Maintenance E-5 802900 DN
Using Electrical Test Equipment E-6 802901 DON
Reading Electrical Diagrams 1 £-7 802902 DN
Reading Electrical Diagrams 2 E-8 802903 DN
Troubleshooting and Emergency 4
Repair of DC Systems _ _ E-9 802904 DN
Troubleshooting and Emergency
Repair of AC Systems E-10 802905 DN
AC Generator Maintenance E41 802906 DN
DC Generator Maintenance E-12 802907 DN
DC Motor Maintenance E13 802908 DN
DC Motor Controller Maintenance 1 E-14 802909 DN
OC Motor Controller Maintenance 2 E-15 802910 DN
Single Phase AC Motor Maintenance E+16 802911 DN
Three Phase AC Motor Maintenance E+17 802912 DN
AC Motor Controller Maintenance 1 . Ea 8 802913 DN
AC Motor Controller Maintenance 2 _ E-19 ; 802914 DN
Synchronous Motor and Controller Maintenance E-20 ; 80291 15 DN
Motor Branch Circuit Protection E-21 802916 DN



62

USACERL IR FE-95/03

10.

11.

12.

13.

14,

15.

16.

Dangerous conditions: When a boiler should not be operated. Causes of
boilers being burned or exploded.
16: Elem. question 12; 22: p.8; 26: p. 33,60,65,154,155,192

Corrosion, pitting, priming and foaming, bulging, bagging: Meaning of
each, where found and how created, danger and remedies.

1: question 69; 16: Elem. questions 3,10; 19: question 37; 22: p.13;

25: Lesson 12 p.5; 26: p. 38,142,183; 27: p.170-172;

30: p.29,31,109,290-294,303,316

Scale and mud: Where found, cause, prevention, effect, dangers, removal.
19: question 41; 22: p.29; 26: p. 35,36,40,59,138,139,143,149,185;
27: p.37,68,170; 30:p.289,293,297,309

Feed water treatment: Meaning, purpose, how applied and controlled,
dangers of over-treatment and under-treatment.

1: questions 69,70,71,73; 19: questions 100,101,102,103,104

26: p.139-143; 27: p.170-176;

30: p.289-296,567-571,557,559-561

Feed water heaters: Types, purpose, advantages, methods of heating feed
water, applications, potential failures.

15: questions 170,191,67,68; 19: questions 47,938,94,95,97;

22: p.14,15,37;

26: p.139; 27: p.68-72; 30: p.91,557-567

Mathematics: a knowledge sufficient to solve any simple problem involving
division and multiplication.

1: questions 51,52; 8: p.1-11; 15: question 10

25: Lesson 1, p.13-17, Lesson 2, p.16-21, Lesson 3, p.12-16

Elementary combustion: Mixtures of combustibles and air, methods of
application and how controlled, purpose of setting, dampers, draft, chimneys
or stacks, hand firing methods, heating values of anthracite or bituminous coal,
oil and gas.

1: questions 27,107; 4: p.1-13; 15: questions 155,156,171,183,231;

16: Elem. questions 19,20,21, Inter. question 17;

19: questions 108,113,114,117,183,184,185, 186,187,192; 22: p.18,19,27

25: lesson 12; 26: p.116-118; 27: p.123-131,; 30: p.99-120,122,123,216



USACERL IR FE-95/03

24. A British Thermal Unit (BTU) is the heat required to raise one (1) pound of
water, at sea level, one (1) degree fahrenheit (F). Therefore, to raise twenty
(20) pounds of water from a street water main temperature of sixty-two (62°F)
degrees to boiling at 212°F, requires:

a. 3000 BTU's

30,000 BTU's

one half hour

15 minutes

epee

5 minutes

25. In the refrigeration cycle, the following actually does the cooling
a. the compressor

the thermostat

the accumulator

the condenser

the evaporator

ome oe

26. A hermetic compressor in a chiller is cooled by
compression

the refrigerant

evaporation

water

coil

ease

27. The heat used to change a liquid to a gas or vapor is called
a. the latent heat of adsorption

the latent heat of absorption

the latent heat of vaporization

the latent heat of fusion

the latent heat of liquids

epee

28. Electricity consumption is measured and sold by
a. the demand

kilovolt ampere (KVA)

kilowatt hour (KWH)

kilowatt (KW)

kilovolt (KV)

mee x



USACERL IR FE-95/03

75

8. POINT OF CONTACT: The USACERL technical point of contact for this project
is Ralph Moshage and Michael Brewer, WATS (800) USA-CERL Ext. 5544/5544, or
Commercial (217) 398-5507/5507, e-mail: moshage%fep@aardvark.cecer.army.mil or
brewer%fep@aardvark.cecer.army.mil. The mailing address is Energy and Utility
Systems Division, P.O. Box 9005, Champaign, IL 61826-9005.



USACERL IR FE-95/03

31.

32.

33.

North American utilities sell electricity in A.C. at 60 Hertz, meaning
direct current with 60 cycles per minute

direct current with 60 cycles per second

alternating current with 60 cycles per minute

alternating current with 60 cycles per second

a higher electric bill than normal

pee op

Transformers
a. provide metering methods
change voltage levels
add capacity
subtract capacity
redirect electrical services

cae Ss

Gate valves are used primarily as
control valves

throttle valves

isolation valves

safety valves

ae op

In the refrigeration cycle, the is immediately downstream of the
expansion device.

a. motor

b. evaporator

c. condenser

d. compressor

Check valves are used to
a. throttle flow
b. relieve excessive pressure
c. allow flow in one direction only
d. relieve excessive level

Latent heat is heat that
a. can be measured with a thermometer
b. cannot be measured with a thermometer
c. is created by pipe friction only
d. is unrelated to heating and refrigeration plant operation .


USACERL IR FE-95/03

51

in clean and serviceable condition. Maintains, services and
repairs all equipment with water conditioning systems. 55%

2 Repairs, troubleshoots and installs large complicated heating
units and systems including oil and/or gas fired systems.
Observes the tests of the operating heating systems in order to
localize malfunctions in automatic controls, pumps and related
components. Inspects, adjusts, and as necessary replaces or
repairs thermostats, switches, fuel cutoff apparatus, burners,
fuel feed, flame safeguard controls, ball bearing thrust bear-
ings, drive rears, springs, gaskets and damaged parts and
electronic and other safety devices. Remove burner, burner
nozzle, strainer and orifice assemblies; dismantles and locates
defects; reassembles and reinstalls components. Services unit by
cleaning filters, strainers, orifices, ignitions electrodes and
adjusting dampers. Removes soot and fly ash from tubes, chamber
ducts, chimneys and breechings. Instalis new heating plants, hot
water boilers furnaces, pumps, controls and connects new equip-
ment to existing facilities. Repairs motorized and gas diaphragm
valves to include replacing gaskets and diaphragm; repacking

motorized valves to prevent leakage around needle valve; and
cleaning and adjusting gas valves to free the operating plunger.
Serves and emergency "no heat" mechanic. Responsible for

operation and maintenance of high pressure boiler plants.
Operates gas, oil fired boiler plants with all pounds of steam
per hour. Maintains proper steam pressure of water temperature
at all times by adjusting controls and regulating auxilairy
equipment. Cleans fire tubes and blows down boilers. Synchro-
nizes boilers when switching from one boiler to another to avoid

loss of steam pressure. Operates and adjusts auxiliary plant
equipment. Inspects boilers and equipment in accordance with
prescribed schedule and check list. Makes adjustments and
repairs to plant and auxiliary equipment, reporting evidence of
deficiiencies requiring major overhaul and repair. Maintains
operating log, recording pertinent informaiton concerning
opeation and maintenance, i.e., fuel, BTU output and plant
efficiency.

Performs refrigeration and air conditioning maintenance tasks.
Works in teh disassembly and repair of heavy and complicated
inductrial and domestic types of refrigertion and air condition-
ing equipment. Representative tasks include cutting and thread-
ing pipe and coil lengths; replacing piston rings, bearing,
connecting rods, pins, crankshafts, belts, valves, gaskets, and
other similar parts; connects or disconnects wiring and lines;
solders and brazes tubing; charges and/or purges refrigeration



24

USACERL IR FE-95/03

some sort of tri-annual licensing or refresher class to maintain the corporate
knowledge base. This is important considering that higher classes of licenses may
be required for operators of large or more complex plants (Appendix J). Many of
the operators who attended the pilot course commented that this was the first
course that they had ever been given in their entire federal service careers. An
unintentional benefit of the course was the cross training among the operators at
an installation. During classroom discussions, many of the operators shared
technical information about the equipment with the class that was apparently new
to the less experienced operators.

U.S. Air Force Boiler Tune-Up Workshop

USACERL developed a series of workshops to train USAF personnel in proper
operation and maintenance procedures. The series covers much more information
than a fourth class operator would be expected to learn. However, the series is
on videotape and available for use inside DOD (Appendix K). The tapes would
assist operators pursing higher levels of qualification.

NUS Training Tapes

The Department of Defense purchased a series of plant maintenance and operation
training videos from the NUS Training Corporation. These tapes cover a wide
variety of topics in basic and advanced skill levels. Additionally, NUS has
produced work books to accompany the tapes. These materials may be a resource
from which an installation could conduct an in-house training course.



54

USACERL IR FE-95/03

Appendix E: Fourth Class Power Engineer

Course Schedule

The course should cover the topics listed in the NIULPE Fourth Class Power Engineer
Curriculum. The NIULPE topics are grouped together with a suggested lecture title
and lecture time. The number in brackets are the specific learning standards from the
NIULPE Curriculum. The only learning objective not mentioned by name in the
NIULPE standard is the training on the legal requirements pertaining to boiler
operations on DOD installations. The instructor should refer to the applicable ASME

Boiler Code articles.

Fourth Class Power Engineer Curriculum:
Topic

Boiler Features (1 to 9) :

Boiler Grates and Burners (21 to 23)

Combustion and Pollution (16,34)

Boiler Controls (33)

Feedwater, Corrosion and Water Treatment (11 to 14)
Pumps and Injectors (17,18)

Steam System and Steam Piping (24,30,31)

Boiler Operations and Maintenance (10,19,20)
Mathematics (15)

Electricity (27)

Air Conditioning, Refrigeration and Air Compressors (25,26,32)
Safety(35) ;

Logs, Log Review, Inspections and Regulations

Total

Lecture Hours

5

; 1.5
15
1.5
15
15
1.5
2
1.5
2.0
3
15
1.5

24.5



USACERL IR FE-95/03

17.

18.

19.

20.

21.

22.

23.

Pumps - simplex, duplex, vacuum: Care, maintenance, purpose, potential
failures, remedies, description.

15: questions 27,98; 16: Inter. question 7;

19: questions 353,355,362,365,366,368,370,374,377,378,385,389,390,
391,393,395; 22: p.10,13,14,37

27: p.95; 30: p.327-381

Injector: Function, principle, care, maintenance, cleaning and inspection, how
often, purpose, valves.
15: question 80; 22: p.18 30: p.328-330

Cleaning and inspection of boilers and setting: Basics.
16: Elem. question 11; 19: questions 36,71; 22: p.8,29;

25: Lesson 5 p.16, Lesson 13; 26: p.157-159; 27: p.187-188,;
30: p.314-317

Starting clean boiler: Manhole covers, how replaced and removed, raising
steam, cutting into live steam header, banking boiler and starting after bank.
22: p.88 25: Lesson 13; 26: p. 150-152; 27: p.183-187; 30: p.283-286

Grate surface, fire line, water level, fire tubes, water tubes, heating
surface: Meaning of these terms.

15: questions 212,213; 16: Elem. questions 6,23, Inter. question 4;

19: questions 1,2,38,39,44,150; 22: p.8,18,28;

25: Lesson 1 p.4, Lesson 5 p.14; 26: p.2,3; 27: p.100-103; 30: p.147-178

Operation of stoker: Starting, purpose, maintenance, care, potential,
failures, advantages and disadvantages.

15: question 212; 16: Elem. question 22; 19: questions 129,131,132,133,
187,188,145,146,152,157,175;

26: p.109-115; 27: p.100-104; 30: p.51-54,148-178

Operation of oil and gas burners and electric boilers: Installation,
starting, care, possible failures, controls, safety devices.

6: p.1-30; 19: questions 125,441;

26: p. 93-104; 27: p.90-100,128,180;

30: p.9,180,189-191,199-212



i. General Comments. (Indicate what you think should be changed to make this report and future
reports of this type more responsive to your needs, more usable, improve readability, etc.)

5. If you would like to be contacted by the personnel who prepared this report to raise specific questions
or discuss the topic, please fill in the following information.

Name:

Telephone Number:

Organization Address:

6. Please mail the completed form to:

Department of the Army

CONSTRUCTION ENGINEERING RESEARCH LABORATORIES
ATTN: CECER-IMT

P.O. Box 9005

Champaign, IL 61826-9005


USACERL IR FE-95/03

43

18.

19.

20.

21.

22.

23.

Boiler feed water pumps operate
a. at higher than boiler pressure
b. at lower than boiler pressure
c. at higher than turbine pressure
d. at lower than turbine pressure
e. at any reasonable pressure

Relief valves are used primarily for relieving pressure in
a. fluid systems
b. gas or vapor systems
c. solids systems
d. steam systems

Pumps are specified by curves, which
a. indicate dimensions
b. indicate motor horsepower
c. indicate size of rotor
d. indicate capacity and head
e. indicate uses

Combustion is actually a process.
a. electrical
b. mechanical
d. chemical
e. pneumatic

Ohms law states that Voltage (E) equals
current (I) times resistance (R)

b. current (I) divided by resistance (R)
c. amps times volts

d. ohms times watts

2

In air conditioning terms, one ton equals
a. 1,000 BTU's per hour
b. 12,000 BTU's per hour
ce. 1,000 KWH
d. 12,000 KWH
e. 500 square feet



USACERL IR FE-95/03

41

7. The most important safety feature of my boiler is
a. the burner switch
b. the low water cut-off
c. the safety valve
d. the fuel pressure regulator
e. the flame control

8. The primary cause of a furnace explosion is
a. low water

low pH

high chlorine

combustible gas build-up

leaking steam drum

ome s

9. One British Thermal Unit (BTU) is equal to the amount of energy needed to
at atmosphere pressure.

increase the temperature of one pound of water one degree Fahrenheit

increase the temperature of one pound of water one degree centigrade

increase the temperature of one gallon of water one degree centigrade

increase the pressure of one gallon of water one PSI

perp

10. An economizer functions as
an air preheater

a superheater

a regulator

a feedwater preheater
a condenser

eae oe

11. A soot (tube) blower should be operated
when windy conditions exist
only when firing with coal
daily

once per shift

when required

eae op



66 USACERL IR FE-95/03

Appendix H: Sample CHPTUTOR Software
Architecture

CERTEST is a computer-based testing tool developed by the U.S. Air Force Space
Command to measure the knowledge level of base facility support personnel. The
CERTEST software could be modified to perform as a computer based tutoring tool.
Figures H1 and H2 show some typical user interfaces screens from a NIULPE test
module written for CERTEST.

| 1102 Water Colurn

1103 Safety Valves

1104 Steam Gauges and Siphons

1105 Feed wat piping and valves

1106 Blowdoun val v: piping and tanks

1107 Fusible plug

1108 Boiler Stays

1109 Common types of boilers - Firetube and Water tube
| 1110 Dangerous Boiler condi tions

1111 Corrosion, pitting, priming, foaming, bulging, bagging

Use the +4, PgUp, and PgDn keys and press ENTER
to select a test.

Figure H1. Sample of test selection screen.



USACERL IR FE-95/03

2 Program Description

NIULPE Standard

For over 20 years, industry has recognized the need to standardize the training
and certification of central heating personnel with the establishment of the
National Institute for the Uniform Licensing of Power Engineers (NIULPE). The
DOD working group chose the NIULPE standard since it has precisely identified
the knowledge areas and the experience requirements for boiler operators. The
NIULPE standard was also chosen since it had an established testing system and
national acceptance of competency criteria. Although the NIULPE standard
addresses refrigeration and air conditioning equipment as well, the trend in staff
reductions necessitates that some boiler operators be tasked to help operate
cooling systems during the summer. The additional knowledge requirements can
be beneficial in those circumstances.

Skills Assessment

USACERL tasked the Science Applications International Corporation (SAIC) in
McLean, VA and Academy of Industrial Training (AIT) in Philadelphia, PA to
conduct an independent review of boiler operator skills by producing a list of
minimum performance skills and knowledge areas that can be objectively
measured. AIT accessed other industry sources outside NIULPE to ascertain the
important skills required to operate central heating plant boilers fired by coal, fuel
oil, or gas. AIT was to differentiate the skills into different grade levels of
operations and maintenance staff. The major system knowledge and skill areas
to be examined by AIT were fuel handling and storage, water treatment,
combustion controls, plant controls, boilers, heat recovery, air pollution control,
waste handling, power generation, plant auxiliaries, and energy distribution
systems. The fundamental factors to be used in defining required job skills will
be safety, reliability, efficiency, environmental impact, and personnel management.



USACERL IR FE-95/03

53

II. Factors (continued):

3. Physical Effort:

Work involves frequent lifting, loading and carrying heating
equipment parts and chemical containers weighing up to 100
pounds, operating hoists, holders, hand trucks and pulleys when
replacing parts or mixing and transporting chemicals. work also
involves working or walking on wet, slippery surfaces, climbing
on and working or walking from high ladders, scaffolds and
platforms. Working in cramped areas, crawling into boilers and
up and around cooling towers. Incumbent is required to stoop,
bend, stretch, kneel and work in tiring and uncomfortable
positions.

4, Working Conditions:

Works in chemical laboratory and boiler rooms on concrete floors
subject to relatively high temperature and is exposed to gas,
carbon monoxide, smoke, ash, dust, fumes and burns from scalding
water, boiler explosion hazards and contact with heated parts of
the system. Subject to injuries from falls, dropping moderately
heavy items, chemical burns, loud, constant noise and use of hand
tools. Subject to exposure to hazardous chemicals such as
algaecide, oxidizers and caustics. Frequently must wear protec-
tive clothing and devices such as goggles, respirators, heavy
aprons, hard hats and gloves and occasionally works outside or in
cramped quarters.

5. Certifications:

Must possess a valid non-commercial drivers license to operate
vehicles to transport tools and equipment to service heating and
cooling equipment. Must possess a valid power engineers license
corresponding to the size and complexity of heating and cooling
equipment operated.



USACERL IR FE-95/03

59

32.

33.
34.
35.

steam traps, reducing valves, sprinkler systems, function, location, operation and
care.

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.
Operation and maintenance of controls.

Air pollution and ecology.

Plant safety.



USACERL IR FE-95/03

13

NAPE Library

NAPE has developed a collection of publications to help its members study for
licensing and certification (Appendix B). These publications have been used by
heating and cooling operator and maintenance personnel in industry to prepare
for license examinations. Additionally, some operators use these publications as
part of their continuing education. USACERL has sent these publications to the
pilot program bases to assess the usefulness of this resource.



USER EVALUATION OF REPORT

REFERENCE: USACERL Interim Report FE-95/03, The Department of Defense Central Heating
Plant Operator Training and Certification Program: An Overview

Please take a few minutes to answer the questions below, tear out this sheet, and return it to USACERL.
As user of this report, your customer comments will provide USACERL with information essential for
improving future reports.

1. Does this report satisfy a need? (Comment on purpose, related project, or other area of interest for
which report will be used.)

2. How, specifically, is the report being used? (Information source, design data or procedure,
management procedure, source of ideas, etc.)

3. Has the information in this report led to any quantitative savings as far as manhours/contract dollars
saved, operating costs avoided, efficiencies achieved, etc.? If so, please elaborate.

4. What is your evaluation of this report in the following areas?

a. Presentation:

b. Completeness:

c. Easy to Understand:

d. Easy to Implement:

e. Adequate Reference Material:

f. Relates to Area of Interest:

g. Did the report meet your expectations?

h. Does the report raise unanswered questions?



34

USACERL IR FE-95/03

18.

19.

20.

21.

22.

23.

Boiler feed water pumps operate
a. at higher than boiler pressure
b. at lower than boiler pressure
c. at higher than turbine pressure
d. at lower than turbine pressure
e. at any reasonable pressure

Safety valves are used primarily for relieving pressure in
a. fluid systems
b. gas or vapor systems
c. solids systems
d. water systems

Pumps are specified by curves, which
a. indicate dimensions
b. indicate motor horsepower
c. indicate size of rotor
d. indicate capacity and head
e. indicate uses

Combustion is actually a process.
a. electrical
b. mechanical
c. chemical
e. pneumatic

Ohms law states that current (I) equals
a. voltage (E) divided by resistance (R)
b. resistance (R) divided by voltage (E)
c. amps times volts
d. volts times watts

In air conditioning terms, one ton equals
a. 1,000 BTU's per hour

b. 12,000 BTU's per hour
c. 1,000 KWH

d. 12,000 KWH

e. 500 square feet



76

USACERL IR FE-95/03

Appendix J: Qualifications Needed for

NIULPE Certification

Fourth Class Engineer
Criterion Qualification
Minimum age 18

Education required

2 years high school, 2 years approved apprenticeship, or ap-
proved OJT

Experience required

2 years minimum examination required-oral, written, practical
maximum engine (prime mover) horsepower requiring licensed
power engineer (unsupervised)-500 HP

Maximum boiler horsepower requiring licensed
power engineer (Unsupervised)

LP-150 HP; HP - 25 BHP

Refrigeration license (unsupervised) 100 tons
Third Class Engineer

Criterion Qualification
Minimum age 20

Education required

High school grad. or GED, three years approved apprenticeship,
or approved OJT

Experience required

3 years minimum

Examination required

Oral, written, practical

Minimum time in previous grade

1 year

Maximum engine (prime mover) horsepower re-
quiring licensed power engineer (unsupervised)

1000 HP

Maximum boiler horsepower requiring licensed
power engineer (unsupervised)

LP-unlimited; HP-200 BHP

Refrigeration license (unsupervised)

500 tons



22 USACERL IR FE-95/03

possibility is to adapt portions of existing Air Force, Navy, Army, and EPA
training books into a single home study book.

Computer-Based Tutor

Many of the bases have computers located in the heating plants for other
administrative functions. USACERL has reviewed the Air Force CERTEST
program and found it to be a good testing tool. However, this product may be even
more beneficial as a tutoring tool. USACERL has constructed a NIULPE tutoring
module with the current CERTEST program to obtain some operator feedback on
the usefulness of such a product (Appendix H). The field demonstrations were
positive and USACERL has drafted a proposal (Appendix I) to build on the
existing CERTEST platform to create a central heating plant tutor (CHPTUTOR)
for use throughout DOD.

Regulation Issues

Even though certification is presently required, the implementation has not fully
met the intent of the regulations. It is essential that the mechanisms be in place
to enable currently employed operators who are motivated to become certified.
Additionally, the job description and job training resources must be consistent
with the certification required. Workforce morale is undermined when the
documented job requirements and certifications are not supported by job training.
The four items of the actual work performed, the documented job description, the
job training resource, and the job skill certification must complement each other
to maintain a quality workforce.

Design a Continuing Education Program

As indicated by the poor performance on the NIULPE tests, DOD installations will
need to implement and maintain continuing training and education resources to
augment a training course. With fewer operators responsible for more complex
equipment, it is critical that the operator be supported with quality training. A
variety of resources should be identified or designed such as home study courses,
computer based tutorial, video training series, or refresher courses. An ongoing
technical training and professional development program is a vital part of
operating DOD plants efficiently, cleanly, and safely.



The contents of this report are not to be used for advertising, publication,
or promotional purposes. Citation of trade names does not constitute an
official endorsement or approval of the use of such commercial products.
The findings of this report are not to be construed as an official
Department of the Army position, unless so designated by other authorized
documents.

DESTROY THIS REPORT WHEN IT IS NO LONGER NEEDED

DO NOT RETURN IT TO THE ORIGINATOR



USACERL IR FE-95/03

36.

37.

40.

41.

A minimum of safety valves are required on all boiler of over
500 sq ft

pmo os
oF wh

Latent heat is heat that
a. can be measured with a thermometer
b. cannot be measured with a thermometer
c. is crested by pipe friction only
d. is unrelated to heating and refrigeration plant operation

Fuses in electrical systems
a. prevent excessive current flows
b. open a circuit in the event of overheating
c. prevent damage to circuit components
d. all the above

Which of the following combustion products is an indication of incomplete
combustion?

a. excess air

b. carbon dioxide

ce. sulfur dioxide

d. carbon monoxide

On a fire tube boiler, the low water shut off valve in the
event of low water level.

a. opens the boiler drains

b. opens the boiler make-up valve

c. increases fuel flow

d. shuts off fuel flow

A pump pumps 500 GPM. If it runs for two hours it will pump
~ a. 8000 gallons
b. 6,000 gallons
c. 60,000 gallons
d. 3,000,000 gallons



USACERL IR FE-95/03

Number | Publication Name Cost
18. Refrigeration Engineer's Guide to Practical Plant Operations, by Baker $3.50
19. Steam Plant Operation $6.00
20. Coal and Its Combustion, by Harrington $5.00
21. Fundamentals of Atomic Energy $3.00
22. How To Prepare for License Examinations, by Hill $3.75
23. Basic Electricity $9.25
24. (Reserved, Not Available)

25. Stationary Engineering $10.00
25A. Stationary Engineering Answer Book $5.00
26. Low Pressure Boilers, by Steingrass $19.50
26A. Low Pressure Boiler Workbook, by Steingrass $11.50
27. High Pressure Boilers, by Steingrass $27.50
28. National Institute for the Uniform Licensing of Power Engineers, Inc. $2.25
29. Practical Electrical Wiring, by Richter $37.00
30. Steam Plant Operation, by Woodrutt $62.00
31. Modern Refrigeration and Air Conditioning,by Althouse $34.00
32, Boiler Operators Workbook, by Wilson $29.50
32A. Boiler Operators Workbook Instructors Guide $8.50
33. (Reserved, Not Available)

34, Diesel Engines and High Compression Gas Engines, by Kates $23.50



USACERL IR FE-95/03 39

47. In some boilers coal is pulverized to

a.

°

increase the percentage of fuel surface area exposed to heat and
oxygen

make it easier to transport to the furnace for burning

decrease the cost of furnace combustion equipment

decrease the amount of pollutants produced

48. Solenoid valves use to operate.

a.

b.
c.
d

manual levers
pneumatic actuators
electro magnetism

. electric motors

49. In the operation of a safety valve, the term “blow down” or “blowback” refers

to

Ber

50.

ao me

the pressure at which the valve opens

the difference between valve opening and closing pressures
the pressure at which the valve closes

the volume of gas released by the valve when it is open

can be found by multiplying volts and amps.-
Ohms
Hertz
Watts
Resistance

Fourth Class Operator Post Test

1. Proper combustion of pulverized coal produces a flame in the color of

a.

b
c
d
e.

yellow

green

red

blue

does not matter



USACERL IR FE-95/03

25

5 Conclusions and Recommendations

This study has identified the major system knowledge and skill areas required to
safely and efficiently operate DOD central energy plants as:

¢ fuel handling and storage

¢ water treatment

* operation of combustion controls
© operation of plant controls

¢ boiler operation

¢ heat recovery

¢ air pollution control

*. waste handling

* power generation

¢ use and maintenance of plant auxiliaries
* energy distribution systems.

In general, coursework should be formulated to address the topics listed in the
NIULPE Fourth Class Power Engineer Curriculum (Appendix F), which gives a
good overview of these needed areas. One area not mentioned in the NIULPE
standard is training in the legal requirements pertaining to boiler operation on
DOD installations. Operator training courses should be designed to address this
as well. Special attention should also be given to the following subjects identified
in the pilot program as relatively weak:

¢ electricity

* required wire sizes

¢ refrigeration cycle

* pump curves

* boiler water level control
° boiler types

¢ boiler blowdown requirements
¢ water level checks

° water treatment

* compressors

¢ mathematics.



USACERL IR FE-95/03

Engineering Service Center (NFESC), the USEPA, and the American Society of
Mechanical Engineers (ASME) to obtain the details of the CAAA 1990 training
and certification module. ASME is developing a qualification standard expected
to be available by late 1996. Meanwhile, the USEPA is under a court order to
deliver a model training and certification program to the individual state EPAs by
30 September 1994, The exact content of this program has not been revealed to
DOD personnel. However, DOD personnel attended a USEPA-sponsored pilot
training course conducted 19-22 April 1994 in Raleigh, NC. The 3%-day course
was similar to the NIULPE course in scope in its emphasis on pollution control
technology, but it did not match the NIULPE course in coverage of material
related to total plant safety, or operation and maintenance.

Since it is one of the largest operators of CEPs in the United States, it is in the
DOD’s interest to minimize the impact of operating these plants on the environ-
ment, both locally and nationally. Additionally, with the downsizing of the DOD
and accompanying reduction in available operating resources in both personnel
and money, it is also in the interest of the DOD to proactively work to meet the
intent of the CAAA and to help the USEPA develop a model training and
certification standard. Such an effort would further prepare the DOD to operate
its plants with fewer personnel and lower fuel costs to free resources for higher
priority programs.

Objective

The overall objective of this study is to identify, develop, and test training methods
to provide central heating plant operators with the knowledge and skills necessary
for their tasks, and to objectively measure and certify operator competence. The
objective of this part of the project was to identify the knowledge and technical
skills required to safely and efficiently operate DOD central energy plants.

Approach

A committee was formed to develop a strategy to implement boiler operator
training and certification standards in the DOD. Members were drawn from
engineering support activities in the Army, Navy and Air Force. This working
group formulated the approach for the pilot program in meetings conducted in
1992. The primary strategy of the pilot program was to use existing industry
accepted standards and products to meet the assessed training and certification
needs of DOD boiler operators. The Office of Personnel Management (OPM) and



USACERL IR FE-95/03

61

. Steam gauge and siphon: Placement, principle, function, care, maintenance,

potential failures, how and when tested.
15: questions 60,66,148; 16: Elem. question 7 19: questions 50,59,60
22: p. 8,17
25: Lesson 6, p.4-8; 26: p.27-31;
27: p.28-30; 30: p.235-237

. Feed water, piping, and valves: Location, care, maintenance, potential failures.

Reason for valves on piping, how kept in good condition. Reason for internal pipe.
15: questions 35,130,173,215; 19: questions 64,65,76,77; 22: p.15
25: Lesson 7, p.2-5; 26: p.50-54;
27: p.72-78,51,52; 30: p.289-290

. Blow down valves, piping and tank: Location, purpose, potential failures, care.

15: question 120; 16: Elem. questions 2,4; 19: questions 31,67,68,70;
22: p.7; 25: Lesson 2, Lesson 7 p.5-13;
26: p.33-34; 27: p.37-39; 30: p.252-256,573-574

. Fusible plug: where placed, purpose, how kept in good condition, possible

failures, description. Installation, when renewed.
15: question 57; 19: questions 48,72;
25: Lesson 2 p.5, Lesson 7 p.1;
26: p.39-40,155,159; 27: p.20; 30: p.233-235,316

. Stays: Placement, purpose, types, description, care advantages of various types,

potential failures.
19: question 35; 22: p.7; 25: Lesson 5 p.8-13; 27: p.12-13; 30: p.83-84

. Two common types of boilers - fire tube and water tube: Description and

characteristics. Qualities of good boiler.
1: questions 2,3,4,43; 15: questions 20,55,140,246;
16: Elem. question 9; 19: questions 1,3,4,5,7,17,19,20,29,42; 22: p.6
25: Lesson 1, Lesson 2, Lesson 3 p.10, Lesson 4;
26: p. 13-19; 27: p.2-11; 30: p.1-19



USACERL IR FE-95/03

Second Class Engineer
Criterion Qualification
Minimum age 21

Education required

High school, four years approved apprenticeship or approved
OUT

Experience required 4 years minimum
Examination required Oral, written, practical
Minimum time in previous grade 1 year

Maximum engine (prime mover) requiring licensed | 2500 BH P

power engineer (unsupervised)

Maximum boiler horsepower requiring licensed 500 BH P

power engineer (unsupervised)

Refrigeration license (unsupervised) 1000 tons

First Class Engineer

Criterion Qualification
Education required High school, technical school, job experience
Experience required 6 years minimum
Examination required Oral, written, practical
Minimum time in previous grade 2 years

Maximum engine (prime mover) horsepower requir- | 7500 HP

ing licensed power engineer (unsupervised)

Maximum boiler horsepower requiring licensed 1500 B HP.

power engineer (unsupervised)

Refrigeration license (unsupervised) 5000 tons



USACERL IR FE-95/03

47

42.

43.

44.

45,

46.

47.

In a fire tube boiler, the flue gases flow through the
a. furnace area
b. the boiler tubes
c. the windbox
d. the water tubes

Heating number 6 fuel oil
a. makes it thicker
b. increases its viscosity
c. decreases its viscosity
d. increases it pour point

A gauge pressure reading of 14.7 psi is equal to an absolute pressure reading
of what?

a. 24.7 psia

b. 0 psia

c. 14.7 psia

d. 29.4 psia

If a boiler has 10,500,000 BTUs of heat input every hour and the steam
leaving the boiler every hour contains 9,500,000 BTUS, the boiler has an
efficiency of
a. 100%
b. 95.5%
c. 90.5%
d 9.5%

What is the purpose of an economizer section of a boiler?
a. To recover flue gas BTUs leaving the boiler
b. To preheat boiler gas before pollution control
c. An economizer preheats primary or secondary air
d. An economizer is used to increase secondary superheat temperature

In some boilers coal is pulverized to
a. increase the percentage of fuel surface area exposed to heat and

oxygen
b. make it easier to transport to the furnace for burning
decrease the cost of furnace combustion equipment
d. decrease the amount of pollutants produced



USACERL IR FE-95/03

49

Appendix D: Sample Job Description
Worksheet

DEPARTMENT OF THE ARMY PREPARED BY (Supervisors Signature?
JOB DESCRIPTION WORKSHEET FOR SUPERVISORS
(or Statement of Major Changes to Job)

For ute of this form, soe CPR 501.65; the proponent agency it ODCSPER,

NUMBER OF INCUMBENTS,
PANY
New s06 (Complete ott of Partstand 1) (XCHANGE TO Jos NUMBER 19579

(Complete Part and Factors in Part Il being changed)

Continue on plain bond paper, if necessary

PART | ~ MAJOR DUTIES

1, MAJOR DUTIES: (For change of existing Job, explain which duties are changing, which remain the tame, and Tor the new duliva, "what done,

For new job, describe “what is done.)
Suggested Title - Boiler Plant Equipment Mechanic
1. Serves as a boiler water analyst performing boiler water control
work in approximately 53 steam generation/heating plants having total
of 75 high/low pressure steam boilers. These boilers range from 45 to
500 horsepower, operate at pressures from 15 to 125 pounds per square
inch gauge (psig), and generate 1000 to 35,000 pounds of steam per
hour and may be active or idle on lay up. Collects and analyzes daily
boiler water samples for specified chemical concentration. Diagnoses
and prescribes required chemical treatment needed to return the boiler
water chemical concentrations to specified ranges that will provide
adequate scale and corrosion protection from dissolved oxygen and
minerals or retest or retreat until chemical concentration and low pH
are stabilized. Collects and analyzes cooling tower samples for
(Continued on next page)

PART Il ~ FACTORS

2. KNOWLEOGE/SKILL: (What procedures, work practices, regulations, processes, principles, sequancer, equipment, tools, facts, and abilitie are
used? To what are they applied, for what purpose, and to what degree or level?)

Must be knowledgeable of boiler water, cooling tower and dual
temperature closed system treatment as it pertains to boilers, cooling
towers and temperature closed system operations including steam and
condensate lines. Tests range in complexity from routine to the
highest difficulty. Must understand the expected results of chemical
treatment, discover unexpected results and determine reasons for
unexpected results by further testing, by applying knowledge of boiler
plant functions, steam usage, and equipment relationship. Must have a
working knowledge of chemistry, especially as applied to water and
water make up. Must be able to read and understand blueprints and
schematics as applied to chemical water, steam, condensate, and
blowdown systems in boiler plant and related areas. Must have
knowledge and skill to repair, troubleshoot and install large
(Continued on next page)

‘B.SUPERVISORY CONTROLS: (How a work assigned? Whal la the responsibility [or carrying work oul? How i work reviewed and by whomiy

Receives verbal instructions, service orders or work orders from
immediate supervisor and General Foreman outlining in general terms
equipment deficiencies and extent of work to be accomplished.
Supplemental instructions such as blueprints, sketches, specifications
and special instructions are provided as necessary. Determines cwn
work methods, plans sequence of work and is responsible for overall
accomplishment using the full range of trade techniques and work
methods, Work is spot checked during performance or upon completion
for satisfactory workmanship.

DA 2", 374WS EDITION OF TJUN GI MAY BE USED,



12 USACERL IR FE-95/03

Resource Identification

USACERL tasked AIT to identify central energy plant operations and mainte-
nance training methods, resources, and reference materials currently available in

. the government and the private sector. The resources identified should help
operators improve or acquire the skills and knowledge identified in the job skill
assessment. Training methods to be considered in this task were to include self-
training programs (textbook, workbook, video-based, and computer-based),
structured on-the-job training, training center-based programs and site-specific
training programs.

Additionally, USACERL reviewed other training mechanisms within the DOD.
USACERL reviewed active duty and civilian staff publications and training aids.
Several initiatives in training and training certification are occurring. The Air
Force has two software products to assist in the training, operation, and
certification of civilian and military engineering support staff. The first product
is a program that assists installation personnel in drafting standard operating
procedures (CheckMaster). The software architecture allows installations to share
common equipment checklists, and the headquarters to promulgate force-wide
procedures. The second product is a program that tests the operator over the
information contained in a set of training videotapes (CERTEST). The software
creates random tests based on the criteria input by the test author. Although the
active duty Navy has used the Personal Qualification Standard (PQS) system for
years, the Navy has recently located the standards on a computer bulletin board
to allow ships to download and update their standards quickly.

Training Course

USACERL tasked SAIC to conduct courses at various installations in DOD. At
this writing, eight courses have been conducted at Army and Navy installations.
The 4'4-day courses are intended to refresh the operators on boiler operations and
systems. To measure the course’s effectiveness, a pre-test and post-test are given.
At the end of the course, a NIULPE Fourth Class Power Engineer examination is
given to the operators. USACERL specified that different instructors be used at
each installation to help filter out the effect of the trainer. Additionally,
USACERL collected data on the effectiveness of the course and test by interview-
ing operators, visiting the heating plants, and observing the conduct of the course.