PART 1 – INSTALLATION

1. The manufacturer of the package boiler is responsible for determining a method of

traceability

2. Un-obstructed air opening shall be sized on the basis of 400 square inch free area per
800,000 Btu/hr. (1 sq. inch = 2000 Btu/hr.)

3. Power ventilators or fans shall be sized on the basis of 0.2 cfm, for each 1000 Btu/hr.

4. Maximum allowable working pressure of the boiler exceeds 100 psig, there shall be two
valves installed

5. Each automatically fired steam boiler shall be equipped with at least two low water fuel
cut-offs

6. Each electric steam boiler of the resistance element type shall be equipped with an
automatic low water cut-offs

7. The lowest visible part of the water gauge glass shall be at least 2 in. above the lowest
permissible water level established by the boiler manufacturer

8. If additional valves are used, the highest pressure setting shall not exceed the maximum
allowable working pressure by more than 3% Answer: 1185

9. Boiler components and sub-components shall be non-destructively examined as required

by the governing code of construction

10. Hot water heating and hot water supply boilers are hot water boilers installed to operate
at pressure not exceeding 160 psig and/or temperatures not exceeding 250F

11. Potable water heaters at pressure not exceeding 160 psig (1100 kpa) and temperatures
not in excess of 210F

12. The temperature rating of such valves or cocks, including all internal components shall
not be less than 250F

13. Size of bottom blow off piping valves and cocks 501 to 1,250  1 in (25 mm)

14. Expansion tanks for systems designed to operate above 30 psig shall be constructed in
accordance with an acceptable code of construction

15. Expansion tank capacity

Up to 650  24

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 16. Steel or wrought iron pipe or tubing is used, the connection and external siphon shall be
not less than NPS ½

17. The lowest visible part of the water gauge glass shall be at least 1 inch above the lowest
permissible water level recommended by the boiler manufacturer

18. In electric boilers of the resistance element type, the lowest visible part of the water
gauge shall be located at least 1 inch above the lowest permissible water level specified
by the manufacturer

19. Each individual steam boiler or each system of commonly connected steam boilers shall
have a control that will cut-off the fuel supply, when the pressure reaches on operating
limit which shall be less than the maximum allowable pressure

20. Each automatically fired hot water heating or hot water supply boiler shall be protected
from over temperature by two temperature operated controls

21. The assembled modular hot water heating boilers shall be equipped with temperature
control

PART 2 - INSPECTION

1. If a vessel has not been properly prepared for an internal inspection, the inspector shall
decline to make the inspection

2. Where the active corrosion is found, the inspector should advice the owner or user to
obtain competent advice regarding proper feed water treatment

3. The fireside surfaces of tubes in horizontal firetube boilers usually deteriorate more
rapidly at the ends nearest the fire

4. Oil or scale in the tubes of water tube boilers is particularly detrimental since this can
cause an insulating effect resulting in rupture

5. Each automatically fired steam boiler is protected from over pressure by not less than
two pressure operated controls, One of which may be an operating control

6. Since combustion occurs at or near the bottom, accumulation of scale or sludge close to
the intense heat can cause overheating and lead to cracking

7. Electric boilers are heated by an electrical energy source either by use of electric
resistant coils or induction coils
8. The distinguishing characteristic of a firetube boiler is that the products of combustion
pass within tubes

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 9. Due to their small size and frequent application where considerable makeup water is
used. Scale development is an important concern  Vertical Firetube

10. Dents can create stress risers that may lead to cracking

11. In external inspection of piping. Past or present evidence of excessive vibration or cyclic
activity such as loose or missing piping supports or piping insulation

12. Pressure relief valves must be periodically tested to ensure that they are free to operate
and will operate in accordance with the requirements of the original code of construction

13. Minor adjustments is defined as no more than twice the permitted set pressure tolerance

14. Pressure greater than 400 psig pressure test to verify nameplate set pressure every 3
year

15. Inter-granular corrosion  Corrosion attacks by a corrosive usually related to the

segregation of specific elements

16. Hydrogen attack occurs in a high temperature, high pressure hydrogen environment that
can degrade the mechanical strength of carbon and low allow steels

17. Magnetic particle examination method can only be used for ferromagnetic materials
18. Liquid penetrant is used to detect discontinuities that are open to the surface such as
cracks, porosity

19. Liquid penetrant is portable fast and require minimal operator training

20. Radiographic film provides permanent record of the results of the examinations

21. Inspection intervals for internal inspection of a vessel with remaining life of 42 months is
21 months (half of the remaining life)

22. Remaining life inspection intervals for exposure to corrosion

= t (actual) – t (required)/corrosion rate
Answer: 2.5

23. The lesser of one half the pressure vessel diameter or 20 inch for vessels with inside
diameter of 60 inch or less (including 58 inch)

24. Organizational commitment and co-operation is required to successfully implement and

maintain a RBI program

PART 3 – REPAIR AND ALTERATION

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1. R certificate holder has the concurrence of the inspector and the jurisdiction where the
pressure retaining item is installed

2. The inspector’s authorization to perform a repair/alteration shall be obtained by the

repair organization prior to initiation of a repair or alteration to a pressure retaining item

3. A holder of a National Board certificate of authorization shall have and maintain a written
quality system

4. National board certificate of authorization for use of the VR symbol stamp  VR repair
organization  hold ASME “V”, “HV”, “UV” or “NV”

5. R certificate holder shall also establish a written procedure where by weld joint are
identified as to the welder or welding operator

6. One or more SWPS (Standard Welding Procedure Specification) may be used as an

alternative to one or more WPS document qualified by the organization making the
repair/alteration provided the organization accepts by certification

7. Minimum temperature for pre-heating

P-No 10 Group 1  175 F

8. Soak Band – region on the spherical or cylindrical shell that will be heated uniformly to
the required PWHT temperature

9. Replacement parts shall be documented on form R-3 and the R symbol stamp applied (R-
1 is for routine repair)

10. Welded reports or replacements of valves, fittings, tubes or pipes NPS 5, where neither
PWHT nor NDE other than visual is required by the original code of construction

11. Installation of new nozzles or openings of such a size and connection type that
reinforcement and strength calculations are not a consideration required by original code
of construction  Example of Repairs

12. The installation of flush patch to a pressure retaining item  Example of repairs

13. Blisters – may be caused by a defect in the metal such as lamination where one side is
exposed to the fire overheats but the other side retains its strength

14. Seal welding of riveted joints, buttstraps, or rivets shall require the approval of the
jurisdiction

15. The user shall prepare the repair plan

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 16. Rerating: current inspection records verify that the pressure retaining item is satisfactory
for the proposed service conditions

17. SA-516  Recommended for firebox repairs

18. Driven plug repair  the land distance between edges of plugs shall be at least equal to
the diameter of the larger plug

NB 263

1. A National Board New Construction commission qualifies an individual to perform

inspection related to boilers and pressure vessels

2. Conflict of interests are activities which directly or indirectly, are detrimental to the
interests of the inspector’s employer or the National Board

3. Continuing education: Each National Board commissioned inspector at least once every 2
years shall complete a NB online training

4. Verify the R certificate holder has a valid National Board “R” certificate of authorization
and activity is permitted under the Scope of the certificate

5. Duties of supervisor includes maintaining competency of the inspector

NB 410

1. Proper treatment of makeup and feed water is necessary to prevent scale, other deposits
and corrosion in pre boiler, boiler steam and condensate systems and to provide and
required steam purity

2. Tubercles are the by-product of and protective housing for oxidation corrosion

3. Makeup water is the major source of carbon dioxide. To control makeup water  Reduce
the carbon dioxide in the boiler system

ASME Section IV

1. The letter “P” used in calculation denotes Design Pressure

2. Calculation Question: Heating surface = Diameter x Length

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 3. Each automatically fired hot water boiler with heat input greater than 400,000 Btu/Hour
shall have an automatic low water fuel cut off that has been designated for hot water
service conforming to UL 353

4. Tanks shall be suitably designed for a minimum hydrostatic test pressure of 75 psi.
Expansion tanks for systems designed to operate above 30 psi shall be constructed in
accordance with Section VIII Division I or Section X

5. The minimum pressure rating of all valves or cocks shall be at least equal to the pressure
stamped upon the boiler, and the temperature rating of such valves or cocks, including
all internal components shall not be less than 250 F

ASME Section VIII – Division I

1. A written radiographic examination procedure is not required for welded joints

2. An as alternative to radiographic examination, ultrasonic examination can be done if the

defects are identified as described in Appendix 12

3. During the heating period, there shall not be a greater variation in temperature
throughout the portion of the vessel being heated than 250 F with any 15 feet of length

ASME Section IX

1. Linear indication  Length is more than three times the width

2. Procedure Qualification Thickness Limits and Test Specimens

Thickness T of test coupon, welded,

1/16 to 3/8 (1.5 to 10), incl.

Range of Thickness T of Base Metal, Qualified, in (mm)

Min: 1/16 (1.5) Max: 2T

3. Welder Qualified with F-No 6 is qualified for All F-No 6

ASME B31.1

1. A pressure relief device set at 1-1/3 times the test pressure

1.84 768 873 1185

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