Looked at 30/06/2009 Consolidation of NBIC QUESTIONS

Marks will only be allocated if references are given

Durban 13/08/2004

1. A National Board “R” Stamp may be issued to a qualified: [1]

a. company that specializes in boilers and pressure vessel repairs
b. manufacturer that holds an ASME “U” Code Stamp
c. utility company
d. all of the above

2. What is meant by the term ‘owner user inspection organisation’ in accordance

with the N.B.I.C? [1]

3. A pressure vessel with a corrosion rate of 1.5mm / yr and an actual thickness

of 62mm has a minimum required thickness of 48mm. When should this
vessel be next inspected in accordance with the N.B.I.C? [3]

4. NBIC rules for replacing items on in-service equipment state that: [1]
a. a replacement may be a repair
b. a replacement cannot be an alteration
c. a replacement shall not allow items fabricated by welding from an
outside source
d. all of the above
e. none of the above

5. Which of the following repairs to pressure vessels by welding are acceptable to

the National Board Inspection Code: [1]
a. defective bolting
b. cast iron sections
c. wasted areas by build-up welding
d. all of the above
e. none of the above

6. The National Board Inspection Code defines: [1]

a. a repair as any work necessary to restore a PRI to a safe and
satisfactory operating condition
b. an alteration as a change in an item described on the original
Manufacturers Data Report which affects pressure containing ability
c. an alteration as an increase in the MAW or temperature

7. When performing repairs on an alteration, legible copies of the completed R1 or

T2 from “Report of Welded Repair or Alteration” together with attachments shall
be distributed to: [1]
a. ASME

1
 b. The authorized inspection agency responsible for the in-service
inspection of the boiler or pressure vessel
c. the owner-user
d. the jurisdiction and National Board when object is so registered
e. only the owner/user responsible for the object
f. the authorized inspection agency that manufactured the object and
the ASME

Durban 27/08/04

1. Pressure testing during in service inspection should always be conducted after

an alternation has been done to the vessel: [1]
a. true
b. false

2. What is meant by the term “owner/user inspection organisation” in accordance

with the NBIC? [1]

3. A 3” NPS forged nozzle is to be replaced on a pressure vessel as part of the

repair organisations repair plan, material certification for the new nozzle is
required in the form of: [1]
a. bills of materials and drawings
b. partial data reports
c. none of the above

4. A pressure vessel with a corrosion rate of 1.5mm / yr and an actual thickness

of 62mm has a minimum required thickness of 48mm. When should this
vessel be next inspected in accordance with the N.B.I.C? [4]

5. What is the minimum required procedure qualification coupon thickness and

minimum groove dimension for repairs 2” deep on base metal 4” thick when
alternative welding methods are adopted under the N.B.I.C? [2]

6. The National Board Inspection Code covers: [1]

a. statutory inspectors
b. insurance agencies
c. equipment manufactures
d. jurisdictional agencies
e. none of the above

7. Establishing and maintaining the quality control system in a fabricating shop

is the responsibility of: [1]
a. the Authorised Inspector
b. the Inspection Agency
c. the National Board
d. the manufacturer or assembler

8. NBIC rules for replacing items on in-service equipment state that:

a. a replacement may be a repair

b. a replacement cannot be an alteration
2
 c. a replacement shall not allow items fabricated by welding from an
outside source
d. all of the above
e. none of the above
1. When the ends of tubes in a fire tube boiler are worn thin due to erosion, may
they be re-ended or seal welded by fusion welding?

2. In making a field inspection of a vertical tubular or locomotive boiler, you find

that the stay bolted furnace sheet is corroded 50 % or more of its original
thickness and for a height of 24” from the mud ring, what method of repair
would you recommend?

4. In repairing a power boiler in service, is it permissible to install a butt-welded

patch of any size (no limitations) in the shell?

6. How would you order repairs to be made to fire cracks that have been found
between the rivet holes and the edge of the lap in an HRT boiler?

7. Upon inspection of a Scotch type welded boiler with a 36” diameter

corrugated furnace you found that the furnace had bulged to the point that it
was considered best to replace the furnace.
Describe the method of removal of the damaged furnace and the installation
of the new one. What parts of the boiler should receive a very close
inspection?

When removing the furnace from the front end of the boiler, perform the
following sequence of steps:

13. Under what circumstances would a test for oxygen content be required on a
boiler of pressure vessel before you enter it for inspection, and what would be
the minimum and maximum percent oxygen required before entry?
REF: NBIC

3
12. What precautions should be taken before entering a boiler or pressure vessel?
Before a boiler or pressure vessel is entered for inspection, the owner or user
shall determine that the object may be safely entered, that there is adequate
ventilation inside the object and it is free of harmful vapors. In all cases,
applicable safety rules and local regulations are to be followed. The inspector
shall discuss with a representative of the owner or user the proper safety
precautions to be taken prior to entry into the vessel. A responsible person
shall stand by the boiler or pressure vessel at all times while the inspector is
inside. For furter procedures for the internal inspection of boilers see NBIC I-
302, and for pressure vessels see NBIC I-5-2
REF: NBIC I-102

10. What is an “alteration” as pertaining to a boiler of pressure vessel?

An alteration is any change in the item described on the original
manufacturers date report, which affects the pressure containing capability of the
boiler or pressure vessel.
Non-physical changes, such as an increase in the maximum allowable working
pressure (internal or external) or design temperature of a boiler or pressure vessel
shall be considered an alteration. A reduction in minimum temperature such that
additional mechanical tests are required shall also be considered an alteration.
REF: NBIC R202

11. A. Is there any difference between a bulge (or bag) and a blister when
found on the shell or drum of a boiler?

a. yes a bulge is cased by overheating of the entire thickness of

the metal, thereby lowering the strength of the metal which is then deformed
by the pressure in the boiler. A blister is caused by a defect in the metal such
as a lamination where the side exposed to the fire overheats but the opposite
retains its strength due to the cooling effect of the boiler water.

B. If a bulge or blister was found in a boiler, can these be repaired without

patching?
How much of a bulge or blister would you allow to be driven back?

b. a bulge of any size can be driven back if the quality of the metal
has not been affected. A blister cannot be driven bak but must
be ground out to sound metal. If the remaining thickness will
calculate for the pressure required, the repair can be accepted;
if not, the entire blistered section must be cut out, and a flush
butt-welded patch installed. A bulge on a water tube should
always be properly repaired
REF: NBIC I –303.6

8. A. What are the “pressure test” requirements following completion of

repairs to a boiler in the field?
A the inspector may require a pressure test after the completion of a
repair to aboiler or pressure vessel.

4
 B. What are the “pressure test” requirements following completion of an
alteration to a boilers?
b. a pressure test shall be applied. Subject to the acceptance of
the jurisdiction, an alternate test or examination may be used.
C. What is the maximum hydro pressure permitted?
c. NBIC I 303.23 I-502.10 Not more than 1-1/2 MAWP
REF: R-308.1, R308.2

9. List the required steps, which must be taken when re-rating a boiler or
pressure vessel by increasing the maximum allowable working pressure (internal or
external or temperature, or decreasing the minimum temperature such that additional
mechanical test are required, shall be considered an alteration and shall be done only
after the following requirements have been met to the satisfaction of the jurisdiction at
the location of the installation:

a. revised calculations verifying the new service conditions shall be

prepared in accordance with the Repair organisations Quality Control System, and be
subject to acceptance by an: Authorised Inspector.
b. all ratings shall be established in accordance with the requirements of
the SAME Code to which the boiler or pressure vessel was built, or by
computation using the appropriate formulas in the latest edition of the ASME
Code, it all essential details are known to definitely comply with the latest
edition of said Code.
a. current inspection records verify that the boiler or pressure vessel is
satisfactory for the proposed service conditions.
b. the boiler or pressure vessel has been pressure tested, as required, for
the new service conditions
REF: NBIX 503