As, / . Explain the procedure adopted for calculating the safety valve set pressire, at ‘Super heater and drum. -(10.Marks) “ C.- What is the difference between safety valve and relief valve? (5 Marks) 4, a What are the precautions to be taken while welding of carbon steel, alloy steel and stainless steel materials during erection or repair of boiler and boiler components? (15 Marks) B. Explain in brief the major steps involved in preparation for inspection of boilers before registration (15 Marks) : 8A) Define tube failure. (2 Marks) * Explain the types of tube failures that may occur in the initial stages of boiler operation till stabilization. (4 Marks) iii) Explain the other types of tube failures that may occur during the long term ; operation of the boilers. (4 Marks) i 8. Write the principles and application of the following NDT methods — Radiographic Testing & Liquid Penetrant Testing. (10 Marks) C. What are the materials used for high temperature applications in Super Critical boilers? Give reasons. (5 +5 Marks) ‘ 6. A. Whatare the requirements to be taken care for the automatic working of the boilers? (15 Marks) B. Name the commonly used specifications for the following - (3.x 5 Marks) i) Plates (Shell, drum) [S200 2 axe ii) Pipesgyrl0 6 ca iil) Tubes GS iv) Castings pos v) Forgings we = ev Seo «= me a B Paper -1 SECOND EXAMINATION FOR COMPETENT PERSONS FOR INSPECTION & CERTIFICATION OF BOILERS — OCTOBER 2012 Boller Design Engineering Date : 07/10/2012 Time : 9:30 — 11:30 Hrs, Marks : 100 Q1_ Each subdivision carries 2 marks. 5X 2= 10 Marks a.) As per the Regulation, whether the drum with ID 1372mm & Thickness of 7smm need heat treatment? li) What are the two types of butt joints used to make Longitudinal / circumferential seams? 'b. When the holes are drilled on the weld seams, what are the precautions to be taken? c. Give the minimum thickness as per Regulation for the class LILI boilers. es i) Whether ERW tubes can be used as stay tubes? il) What is the minimum thickness of the stay tube of diameter 63.5mm as per code? €. i) How many Safety Valves are to be provided in the boiler to relieve the Pressure? ii) What is the minimum diameter of the Safety Valve? Q2 Refer the sketch 1 of a sample steam drum .The Steam drum is to be constructed in accordance with the requirements of IBR. It has an inside diameter of 1371 mm and an internal design pressure of 133 Kg/Sqem(g) at 332 °C. Calculate the thickness of Dished Head as per the appropriate regulations. (30 Marks ) Note: ‘1. Material used for dished head is SA 16 Gr.70 and the values of allowable stress value Provided in the governing code of plate material are given in the table: Maximum allowable stress value for SA 516 Gr. 70 Temp? C 350 132 128 2. Consider the forming allowance as 12.5%. Allowable stress value in | Mpa 3. Additional reinforcement pad is not recommended for openings17) 18) 19) 20) 21) 22) 23) 24) 25) 26) In testing of springs at manufacturers end, the permanent set in spring permitted shall be a) 3% b) 10% ) 5% of the free length of spring The outside diameter of water gauge glass shall be between 2)3/8" &%" b) %” & 5/8” A" & ‘ma boiler with wet back reversing chamber fusible plug shall be fitted a)on the front tube plate bjon the front & rear tube plate cJon the crown of reversing chamber & tube plates d)on the crown of reversing chamber & rear tube plate The heat treatment of tubes / pipes conforming to SA 213 T11 / SA 335 P11 may be waived if at < 15mm, OD <4”, preheating to 150% b)t< 13mm, OD < 127mm, pre heating to 125% c}t= 132mm, OD = 5”, preheating to 200° The diameter of tube hole is 2.5”, the minimum thickness of tube plate in tube are shall be ay’ b) 5/3" os/i6” A welder qualified in pipe welding horizontally fixed position is eligible to weld in vertically fixed position a)True b) False The State Government may, by Notification in official gazette, exclude any specified area from the operation of all or any specified provision of Act. a)True : b) False Alignment tolerance of sections to be butt welded for thickness (t) above 51 mm on longitudinal direction in a cylindrical shell is a)Lesser of 1/6 t or 9mm b)Lesser of 1/8 t or Smm c)lesser of 1/10 tor 9mm d)Lesser of 1/8 t or 19 mm ‘Any firm seeking recognition as a repairer, for repair of boilers and steam pipes shall apply to a) Secretary Central Boiler Board ») Chief inspector of Boilers of state where boiler is installed ¢) The owner of the boiler 4d) Chief inspector of Boilers of state where boiler was manufactured ‘A candidate should obtain marks awarded in accordance with Form Xil not less than a) 40% in oral & 55% in practical b) 50% in oral & 65% in practical +) 60% in oral & 75% in practical 4d) 70% in oral & 85% in practical3 An integral Economiser is located the convection pass of the bolle with the following design mevemetors. Check whether the cols can be used for @ maximum working pressure of 177 KgiSaem(o). : (20 Maiks) Tubesize 51 x3.6mm Material - SA210GrA1 Design Temp - 345°C ‘Allowable stress for the material can be taken from the following table. (emp in 325, [360___[ 375 [Stress value in Ka/SqCm 7202.5 | 117 40712 {fot found suitable, calculate the tube thickness required to withstand this pressure. 24 Find the thickness of the compensating plate to be provided around tne opening in a shell type boiler, given the following design details. (20 Marks) Width of the opening w 150 mm Sheil Actual thickness T. 32mm ~ Unpierced shell thickness tT 28mm~ Branch thickness Ts. 28mm Min thickness required for the Branch Tz 22.6mm ‘Allowable stress in Kg/SqCm for the various components can Be taken from the following Table: feo ‘Sheil Plate S__| 602 Branch. ‘S2_| 762 ‘Compensating Pad 700, Note : 1) There are no external loads acting on the pipe 2) The weld area is negligible.Find the minimum required tube thickness for primary convection ‘super heater coils of single loop with the following parameters. (20 marks) Tube size & Specification -OD 51mm &SA210Gr.A1 Maximum working pressure 68 kg/sqem ( g ) Tube inside fluid temperature - 333°. Values of allowable stress value for SA 210 Gr A1 provided in governing code of tube material is given in the table: Temp? C 325 350 375 400 Allowable een 118 417 105 88.9 value in MPa iz t Note: Commercially available thickness for OD 51 mm & SA 210 Gr.A1 tube are 3.25 mm, 3.66 mm, 4.0 mm 4.5 mm & 5.00 mm1 HOLaYS STIVETT WAY NVALS xPaper 2 SECOND EXAMINATION FOR COMPETENT PERSONS FOR INSPECTION AND CERTIFICATION OF BOILERS - OCTOBER ~ 2012 REGULATIONS, WELDING, HEAT TREATMENT AND SAFETY Date : 07/10/2012 Time : 11:30 ~ 12:30 Hrs. Marks : 100 1) The certificate issued by well known tube makers for the tubes manufactured by them is in 2) 3) 4) 5) 6) IBR certificate format a)Form IA b) Form iil B ©)Form iit 0 4d) Forme During bevelling for fusion welding of longitudinal seams, bevelling from both sides is, required for thickness more than a)10 MM »)20 MM 25 MM )40 mM Exemption from,P.W.H.T with additional conditions for the 1Cr % Mo is provided for thickness not exceeding a) 19MM b) 13MM 9 8mm - Any person is punishable under Boilers Act for a) Not reporting an accident b) Tampering safety valve to render c)_ Not engraving the register number d) All of the above In carbon steel plates the sulphur & phosphorous content shall not exceed a) 0.06% b) 1% ¢} 0.05% Hydraulic test of tubes / pipes are mandatory if the tubes are subjected to Non Destructive Testing like Ultrasonic, Eddy current / stray flux testing a) Yes b) No c)as decided by Inspecting Authority in operative7) 8) 9) 10) 11) 12) 13) 14) 15) 16) The minimum thickness of boiler quality plate shall be a) 3/8" b) x" 5/3" qd) Tube holes in welded seams should be avoided as far as possible a) True b) False ‘he percentage of Chromium (Cx) & Molybdenum (Mo) in tubes / pipes to specification T91/ P91 shall be a) 0.8 to 1.25%; & 0.45 to 0.70% b) 1.9 to 2.6%; & 0.87 to 1.13% 5 0.8 to 1.2% d) 8.0 t0 9.5%; & 0.85 to 1.05% {he quality factor taken in high class castings for computation of permissible working stress shall ufficient metal to permit preparation of retest specimens in reminder of the test Plates, test specimen may be cut from the opposite side of longitudinal seam a) True b) False . On completion of seams, heat treatment shall not be necessary for carbon steel if thickness of art weld recess and carbon content shall not exceed a) 22mm,0.3% b) 20mm,0.25% ¢) 20mm, 0.396 The temperature of water used in hydraulic testing shall be a)2o°ert<50°; b) 30°coteast ¢) 25%e>t<50°c Where t= temperature Fhe working metal temperature used in design yield point (0.2%) proof stress value for super heated steam shall be a)corresponding to W.P +50°F b]drum steam temperature +50°F ¢) super heated steam temperature +50°F ‘The strength of the ligaments between tube holes which are subjected to longitudinal stress Shall be at least one-half times of the strength of tube holes subjected to circumferential stress a) True b) False Bolers fitted with integral super heaters itis mandatory to fit an additional safety valve atthe end of SH outlet header a) True b) False27) 28) 29) 30) 31) 32) 33) 34) 35) 36) The design metal temperature should not exceed _degree C for seamless carbon steel pipe as er IBR a)a24 deg c b)434 degC 444 deg C )454 degC For plates not for hot forming and thickness above 12mm the supplied condition is a) Un-normalized b) As rolled ©) Normalized Butt welds of tubular products required 100% R.T in case the component bore exceeds a) 88mm b) 102mm. ©) 178mm ‘The minimum angle of the bend for the Grade A steel castings is a) 90” b) 120° ©) 180° In segmental bends / fabricated bends, the angle between the axis of adjoining sections does not exceed a) 45% b) 60° 30° The minimum hydraulic test pressure on subsequent examination shall be a) 1time WP. b)1.5 times WP. 0) 1-1/4 times W.P Heating surface means total surface of a)plates & tubes exposed to flame b)plates & tubes on water side o)plates & tubes exposed to heat on one side and in contact with water on the other side “ The manufacturer shall maintain the records of boilers / economizer / steam pipes as the case may be ( including the data booklet / forms) for a minimum period of a)Tyears b) 10years o) Syears Inspecting Authority's Certificate for inspection under construction of Economizers a)Form I b) Form vill ¢) Form Vil ‘The maximum permissible variation in diameter at any cross section of internal flue shall be a)Not more than %" or half of the plate thickness whichever is greater. ~ b)Not more than %” Not more than %" of plate thickness37) 38) 39) 40) 41) 42) 44) 45) 46) Where cross tubes are fitted in vertical boiler, the projection shall be a)not less than 3/8” & not more than %” b)not less than ” & not more than 5/8” not less than 5/8” & not more than 3/4” The stress relieving part shall be left to cool in the furnace upto a maximum temperature 2) 400°C b)as0%c ©) 300°C Two plates of thickness 25mm & 35mm are butt welded, the thickness to be considered in heat treatment for calculation soaking time shall be a)25mm b) 35mm, ¢) the thickness of weld joint Compensation for openings in shell in, shell type boilers is mandatory ‘a)Where the width of opening exceeds 2.5 times t+2.75" b)Where the width of opening exceeds 1.5times t+2.5" )Where the width of opening exceeds 1.5times t+3.0" The period permitted for periodic check test of electrodes shall be every a) 6months b) One year ¢) at the discretion of inspecting Authority The thickness of the furnace or fire box whether plain or corrugated shall not exceed a)%" b) 5/8" g7/s" ‘The maximum permissible vari boilers shall not exceed ayy by" ) the thickness of the plate Plain tubes subjected to external pressure shall be fitted by a) expanded & bell mouthed, beaded b) by welding at gas inlet end ©) screwed and welded ¢) both (a) & (b) Minimum size (i.e) Outside diameter x Thickness of stay tube subjected to external pressure shall be a) 25.4mm, 2.5mm, b) 32mm, 3mm ©) 38mm, 2.8mm The percentage sensitivity required for thick section radioscopic images shall be a)3% b) 2% ©) spatial resolutions 3lines per mm ces of horizontal in diameter at any cross section of fur47) The minimum thickness of tube plate for which heat treatment may be waived when tubes are strength welded shall be a) 18mm b) 25mm ¢) 22mm 48) The minimum size of the sight / cleaning holes in boilers shall be a) 4" x3" b)3.5" x25" oa"x7" 49) The minimum factor of safety required in desi welded/seamless forged drum a)3.5 b)4 <) 5.13, 4) 3.99 50) The maximum diameter and gauge length for all weld test specimen of butt joints of fusion welded drums a) do=20mm, b) ¢)_ Discretion of inspecting Authority ‘Where do Out side diameterPaper -3 SECOND EXAMINATION FOR COMPETENT PERSONS FOR INSPECTION & CERTIFICATION OF BOILERS - OCTOBER 2012 OPERATION & MAINTENANCE (O & M) COMMISSIONING, NDT, MATERIALS AND ERECTION Date : 07/10/2012 Time : 14:00 — 17:00 Hrs. Marks : 150 Note : 1. Answer any 5 questions 2, Use Sketches where ever required to explain even if not explicitly asked 117A. How boilers are classified? Explain in brief any two types of boilers.(15 Marks) 8. What are the differences between Super Heater and Reheater? Explain in detail with pressure and temperature parameters? Explain the reason for incorporating reheater in thermal power plant (15 Marks) 2. A. Define as per boilers act 1923 (10 Marks) Owner -f)Steam pipe ~“i)Super Heater <-49)Boiler Component Competent Authority 8. What are the procedures to be followed for inspection of installed boilers? (Mention any five) (10 Marks) C,-When a boiler is subjected to Remnant Life Assessment (RLA)? Explain the steps involved in RLA. (10 Marks) 3. A. Explain the importance of conducting the Hydraulic test for boiler. Explain — the difference between conducting the hydraulic test for boiler and boiler components. (15 Marks)