Free Boilermaker – Pressure Vessel Practice Questions

Sample Practice Questions

Try these 10 sample questions from the Boilermaker – Pressure Vessel practice bank. Each includes the answer and explanation. Continue with the interactive practice above to review the full question set.

1. 1While dressing a fitting on a bench grinder, a boilermaker adjusts its work rest. What is the greatest permitted gap between the rest and the wheel surface?

   1. A. 1/16 inch
   2. B. 1/8 inch
   3. C. 1/4 inch
   4. D. 3/8 inch

   Answer: B

   Explanation: OSHA states, "Such work rests shall be kept at a distance not to exceed one-eighth inch from the surface of the wheel." The largest permitted gap is therefore 1/8 inch.

   Reference: OSHA 29 CFR 1926.303 — Abrasive wheels and tools — 29 CFR 1926.303(c)(2)

2. 2At a boiler construction site, stored oxygen cylinders are placed near stored fuel-gas cylinders without a fire-rated separating barrier. What is the minimum required separation distance?

   1. A. 10 feet
   2. B. 15 feet
   3. C. 20 feet
   4. D. 25 feet

   Answer: C

   Explanation: OSHA states, "Oxygen cylinders in storage shall be separated from fuel-gas cylinders or combustible materials (especially oil or grease), a minimum distance of 20 feet (6.1 m) or by a noncombustible barrier". With no qualifying barrier, the minimum distance is 20 feet.

   Reference: OSHA 29 CFR 1926.350 — Gas welding and cutting — 29 CFR 1926.350(a)(10)

3. 3An arc-welding cable has an ordinary splice near the electrode holder. Absent the insulated-connector exception, what minimum splice-free length must a boilermaker verify from the holder end?

   1. A. 5 feet
   2. B. 10 feet
   3. C. 15 feet
   4. D. 20 feet

   Answer: B

   Explanation: OSHA states, "Only cable free from repair or splices for a minimum distance of 10 feet from the cable end to which the electrode holder is connected shall be used, except that cables with standard insulated connectors or with splices whose insulating quality is equal to that of the cable are permitted." The ordinary splice must be at least 10 feet away.

   Reference: OSHA 29 CFR 1926.351 — Arc welding and cutting — 29 CFR 1926.351(b)(2)

4. 4A boilermaker must install a valve to regulate flow through a boiler piping branch, rather than merely isolate the line. Which valve type has the throttling action described by DOE?

   1. A. Globe valve
   2. B. Gate valve
   3. C. Swing check valve
   4. D. Safety valve

   Answer: A

   Explanation: DOE states, "This characteristic gives the globe valve good throttling ability, which permits its use in regulating flow." A gate valve is described as a start-or-stop device rather than a throttling valve.

   Reference: DOE Fundamentals Handbook: Mechanical Science, Volume 2 — Module 4, Types of Valves, Globe Valves, p. 15

5. 5At the start of a construction shift, a boilermaker is preparing rigging for a boiler drum lift. When does OSHA require the rigging equipment to be inspected?

   1. A. Before use on each shift and as needed during use
   2. B. Before its first job only and after any repair
   3. C. After each completed lift and at the end of the shift
   4. D. At monthly intervals and after an overload event

   Answer: A

   Explanation: OSHA states, "Rigging equipment for material handling shall be inspected prior to use on each shift and as necessary during its use to ensure that it is safe." The planned lift is construction material handling, so the pre-use shift inspection applies.

   Reference: OSHA 29 CFR 1926.251: Rigging Equipment for Material Handling — 29 CFR 1926.251(a)(1)

6. 6A boilermaker must confirm the identification number of a boiler erection drawing before using it. Which drawing area normally contains that number?

   1. A. The title block
   2. B. The revision block
   3. C. The drawing grid
   4. D. The notes legend

   Answer: A

   Explanation: DOE states, "The first area of the title block contains the drawing title, the drawing number, and lists the location, the site, or the vendor." The identification number is therefore sought in the title block.

   Reference: DOE Fundamentals Handbook: Engineering Symbology, Prints, and Drawings, Volume 1 — Module 1, Anatomy of a Drawing, The Title Block, p. 3

7. 7A boilermaker has measured a boiler-tube replacement length of 3.5 feet and needs to mark it in inches. What length should be marked?

   1. A. 42 inches
   2. B. 36 inches
   3. C. 38 inches
   4. D. 48 inches

   Answer: A

   Explanation: DOE gives the conversion "1 foot = 12 inches." Multiplying 3.5 feet by 12 gives 42 inches. The other values result from rounding the feet first or using the wrong conversion factor.

   Reference: DOE Fundamentals Handbook: Classical Physics — Unit Systems, Unit Conversions, p. 10

8. 8A boilermaker inspects a firetube boiler during a component replacement. Which fluid normally passes inside its boiler tubes?

   1. A. The combustion gases
   2. B. The boiler feedwater
   3. C. The separated steam
   4. D. The returned condensate

   Answer: A

   Explanation: DOE states, "In firetube boilers, the combustion gases pass inside boiler tubes, and heat is transferred to water between the tubes and the outer shell." The tubes carry hot gas rather than boiler water.

   Reference: DOE: Improving Steam System Performance, A Sourcebook for Industry — Steam System Basics, Generation, Boilers, Firetube Boilers, p. 4

9. 9On a liquid process piping job using UFGS 40 05 13, a steel line needs a new tap into its pipe wall. Which connection is specified for the steel pipe?

   1. A. A service saddle connection
   2. B. A welded threadolet connection
   3. C. A tapping boss in a fitting
   4. D. A tapping boss in a valve body

   Answer: B

   Explanation: "Make taps to steel piping only with a welded threadolet connection." The steel-pipe tap calls for a welded threadolet. The other connection locations are listed for ductile iron piping.

   Reference: Unified Facilities Guide Specification 40 05 13, Pipelines, Liquid Process Piping — Section 3.3.8, Pipe Taps, p. 95

10. 10Access to a boiler tube's exterior is restricted near a drum. Which nondestructive method described by DOE uses a rotating mirror to direct an ultrasonic signal and scan the tube from its inside diameter?

    1. A. Contact ultrasonic thickness testing
    2. B. Internal rotating inspection system
    3. C. Immersion ultrasonic testing
    4. D. Wet fluorescent magnetic-particle testing

    Answer: B

    Explanation: "internal rotating inspection system (IRIS)-based techniques in which the UT signal is reflected from a high rpm rotating mirror to scan tubes from the ID" IRIS directs the ultrasonic signal with a rotating mirror from inside the tube; contact UTT uses an exterior accessible surface, immersion UT uses a multitransducer probe, and WFMT examines external weld surfaces.

    Reference: DOE Operations & Maintenance Best Practices Guide, Release 3.0 — Section 9.2, Boilers, Tubing Assessment, p. 9.5