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B.m. R.e.c.c.n.
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  • 1. 
     The channel head cover on an exchanger is used on the__________
    • A. 

      Bundle

    • B. 

      Nozzles

    • C. 

      Shell side

    • D. 

      Tube side


  • 2. 
         Who is responsible for housekeeping?
    • A. 

      Laborers

    • B. 

      Helpers

    • C. 

      Individual workers

    • D. 

      Sub-contractors


  • 3. 
        Where is a demister pad usually located?
    • A. 

      Bottom of tower

    • B. 

      Top of tower

    • C. 

      Side of tower

    • D. 

      At the sump


  • 4. 
       What is the standard hydro-test pressure after a routine boiler repair?
    • A. 

      Operating pressure

    • B. 

      Design pressure

    • C. 

      1 1/2 times the operating pressure

    • D. 

      1 1/2 times the design pressure


  • 5. 
    1.       All of the following are parts of a tower EXCEPT
    • A. 

      Clips

    • B. 

      A downcomer

    • C. 

      An internal man-way

    • D. 

      An orfice


  • 6. 
    1.       When may guards and other safety devices be removed from equipment?
    • A. 

      When they are in the way

    • B. 

      When they become damaged

    • C. 

      When authorized equipment repair is being performed

    • D. 

      When there is inadequate space in which to perform work


  • 7. 
    1.       What does “3-inch G.A.V.A.” on a piping isometric mean?
    • A. 

      3-inch guage

    • B. 

      3-inch gate variance

    • C. 

      3-inch gge variance

    • D. 

      3-inch gate valve


  • 8. 
    1.       What indicates the direction of flow on a check valve?
    • A. 

      Flange size

    • B. 

      The arrow on the valve

    • C. 

      Valve seat

    • D. 

      Pressue rating


  • 9. 
    1.       What types of valves are typically used on a sight glass to direct flow?
    • A. 

      Three way valve

    • B. 

      Gate valves

    • C. 

      Globe valves

    • D. 

      Plug valves


  • 10. 
    1.       Why are metal tags installed on 90-degree turns on reactors?
    • A. 

      To comply with company policy

    • B. 

      So that leaks can be documented

    • C. 

      For inspection puropses

    • D. 

      Tags are not required by DOT


  • 11. 
    1.       Why is a Monel gasket used in HF acid piping?
    • A. 

      Because of it's high resistance to acid

    • B. 

      Because it willcompress readily when subjected to pressure

    • C. 

      Because it will flex to adjust with any pipe movement

    • D. 

      Because of it's high tensile strength


  • 12. 
    1.       Dampers are used on the PRIMARY air ports to control the__________
    • A. 

      Burner fuel supply

    • B. 

      Pressure on the primary wind box

    • C. 

      Air flow into the furnace

    • D. 

      Air out of the box


  • 13. 
    1.       What should be verified before a wall burner is pulled for inspection?
    • A. 

      The feed valve must be shut

    • B. 

      The fuel gas valve must be shut

    • C. 

      Lube oil valve must be shut

    • D. 

      The quench oil valve must be shut


  • 14. 
    1.       A 1-inch plate is to be cut.  Why should an acetylene regulator on a cutting rig NOT be adjusted over, 15 psi?
    • A. 

      Most acetylene cylinders are too small to put this volume of flow

    • B. 

      It costs the company money

    • C. 

      Acetylene is unstable above this pressure

    • D. 

      Most cutting torches will not accept this pressure


  • 15. 
    1.       When a tube “Dutchman” is used, what size gap should be left between the “Dutchman” and the tube?
    • A. 

      1/8-inch bottom and 3/32-inch top

    • B. 

      1/8-inch bottom and 1/8-inch top

    • C. 

      1/16-inch bottom and 1/16-inch top

    • D. 

      3/32-inch bottom and 1/8-inch top


  • 16. 
    1.       Pipe stamped with the Code 316L or 304L denotes what type or grade of piping and fittings?
    • A. 

      Stainless steel

    • B. 

      Carbon steel

    • C. 

      Copper

    • D. 

      Chrome


  • 17. 
    1.       What is indicated by the notation “3-inch, 150#” on an isometric drawing?
    • A. 

      3-inch radius, 150# flange

    • B. 

      3-inch diameter, 150# torque

    • C. 

      3-inch diameter, 150# line

    • D. 

      3-inch diameter, 150# flange


  • 18. 
    1.       What is the volume of a rectangular electrical box if the with is 3 ¼ inches, the length is 4 ½, and the depth is 1 ¾ inches?
    • A. 

      26.600 cubic inches

    • B. 

      2.560 cubic inches

    • C. 

      0.256 cubic inches

    • D. 

      None of the above


  • 19. 
     What is the pressure differential hydro-test on an exchanger?
    • A. 

      A hydro-test that is 1 ½ times the operating pressure

    • B. 

      A hydro-test in which the shell and tube are pressurized at the same time

    • C. 

      A hydro-test in which the shell and tube side are hydro-tested at different times

    • D. 

      A hydro-test that is different when fire water is used on the shell and the hydro-pump is used on the tubes


  • 20. 
    What is a “dummy leg” used for?
    • A. 

      Joining two pieces of pipe

    • B. 

      Holding up tray rings

    • C. 

      Supporting piping

    • D. 

      Stopping pipes from moving in their rack


  • 21. 
    A hand-hole plug is removed.  How should the hole be repaired?
    • A. 

      Pad welding to the original size

    • B. 

      Install a plug and fill it in with weld metal

    • C. 

      Install a plug that is the correct size

    • D. 

      Modify the plug and install it to fit


  • 22. 
    All of the following are major components of a tower EXCEPT?
    • A. 

      A demisster pad

    • B. 

      Trays

    • C. 

      Man-ways

    • D. 

      Channel head


  • 23. 
    What do the letters “WOL” on a blueprint stand for?
    • A. 

      Water On Line

    • B. 

      Weld-O-Let

    • C. 

      Weld on Line

    • D. 

      Weld On Level


  • 24. 
    What should be used to put screwed fittings together for a steam process?
    • A. 

      Teflon Tape

    • B. 

      High-temp anti-seize

    • C. 

      WD-40

    • D. 

      Teflon Paste


  • 25. 
    A right triangle has three angles that add up to 180 degrees.  What are the sizes of each of each of the three angles?
    • A. 

      36, 90, 54 degrees

    • B. 

      50, 45, 85 degrees

    • C. 

      68, 45, 67 degrees

    • D. 

      95, 40, 45 degrees


  • 26. 
    What are spacers used for when an exchanger is blinded?  
    • A. 

      They are used instead of a gasket on one side of the exchanger flange

    • B. 

      They are used to space open the exchanger side for steaming or nitrogen purge

    • C. 

      They are used to strengthen a thin slip blind

    • D. 

      They are used to achieve proper bolt engagement


  • 27. 
     Eye bolts, anchor bolts, and self-tapping bolts ate all types of__________  
    • A. 

      Fasteners

    • B. 

      Aligning tools

    • C. 

      Trim

    • D. 

      Test equipment


  • 28. 
    How much is 3-inches in hundredths of a foot?  
    • A. 

      0.15

    • B. 

      0.25

    • C. 

      0.35

    • D. 

      0.5


  • 29. 
    Why does an operator rod-out a drain valve?  
    • A. 

      To see if the valve is working

    • B. 

      To ensure the line is clear

    • C. 

      To ensure the line is pressured up

    • D. 

      To see is the valve is within specs


  • 30. 
    Typically, what is the hydro-test pressure of an exchanger with an operating pressure of 400 psi?  
    • A. 

      400 psi

    • B. 

      500 psi

    • C. 

      600 psi

    • D. 

      800 psi


  • 31. 
    What power source is used to run a tugger?  
    • A. 

      Electricity

    • B. 

      Gas Motor

    • C. 

      Compressed Air

    • D. 

      Hydraulics


  • 32. 
    What holds the trays to the rings in a tower?  
    • A. 

      Weir plates

    • B. 

      Down-comers

    • C. 

      Tray clips

    • D. 

      Ring clamps


  • 33. 
    1.       What grade number is found on the bolts on a reactor that operates at high temperatures? a.       L-5 b.       A-35 c.        B-16 d.       B-7
    • A. 

      L-5

    • B. 

      A-35

    • C. 

      B-16

    • D. 

      B-7


  • 34. 
     Which of the following items are used for heavy rigging?
    • A. 

      Rope and chain link

    • B. 

      Slings, shackels, and spreader beam

    • C. 

      Chain, rope, bolts, and nuts

    • D. 

      Lifting eye and rope


  • 35. 
    What does a grooved nut on an oxyacetylene rig indicate?  
    • A. 

      The right hand thread is for oxygen use only

    • B. 

      The left hand thread is for oxygen use only

    • C. 

      The right hand thread is for acetylene use only

    • D. 

      The left hand thread is for acetylene use only


  • 36. 
     What are thermocouples used for?  
    • A. 

      Measuring the water flow through tubes

    • B. 

      Measuring the gas temperature in the furnance

    • C. 

      Indicating the temperature of the metal to which it is attached

    • D. 

      Indicating the steam flow through the holes


  • 37. 
     Which gas passes through the center in a cutting torch tip?  
    • A. 

      Acetylene

    • B. 

      Oxygen

    • C. 

      Argon

    • D. 

      Nitrogen


  • 38. 
     What should be done before furnace fittings for tube replacements are grounded?  
    • A. 

      The spring canister should be inspected

    • B. 

      The inside of the fitting should be inspected

    • C. 

      The air tugger should be inspected

    • D. 

      The retaining pin should be inspected


  • 39. 
    1.       What should be used on the bolts of a reactor that operates at high temperatures? a.       Heavy-oil b.       Teflon c.        Nickel anti-seize d.       WD-40
    • A. 

      Heavy oil

    • B. 

      Teflon

    • C. 

      Nickel anti-seize

    • D. 

      WD-40


  • 40. 
    What determines the type of bolts to be put back in an exchanger so that it can be bolted back together?  
    • A. 

      The amount of threads on stud bolts

    • B. 

      The service exchanger is used for and the stencil on the old bolts

    • C. 

      Size does not matter if the lenght is the same as the length of the old bolts

    • D. 

      Any available bolts may be used


  • 41. 
    What type of diagram provides and overall view of the operational aspects of a process system?  
    • A. 

      Plan view

    • B. 

      P&ID

    • C. 

      Section view

    • D. 

      Isometric drawing


  • 42. 
    What is the basic formula for determining the CORRECT wrench size, per stud size?  
    • A. 

      2 times the stud diameter

    • B. 

      1 1/2 times the stud diameter plus 1/4 inch

    • C. 

      1 1/2 times the stud diameter plus 1/8 inch

    • D. 

      1 1/2 times the stud diameter plus 1/16 inch


  • 43. 
    What is a hammer wrench commonly used for?  
    • A. 

      Aligning flanges

    • B. 

      Breaking difficult bolts

    • C. 

      Chiseling try hardware

    • D. 

      Separating flanges


  • 44. 
    What is the standard hand signal used to instruct a crane operator to lower a load?
    • A. 

      Point an index finger skyward and move it in a circular motion

    • B. 

      Point an index finger at the load and move it in a circular motion

    • C. 

      Point an index finger skyward and move it in a circular motion while hoding the other hand flat above the signal

    • D. 

      Point an index finger to the ground and move it in a circular motion while holding the other hand directly below the signal


  • 45. 
    What information MUST a boilermaker know before blinding a tower?  
    • A. 

      Pipe size

    • B. 

      Circumference of the tower

    • C. 

      Flange size

    • D. 

      Tower height


  • 46. 
    What should a boilermaker do first when preparing for the evacuation of a reactor?  
    • A. 

      Evacuate the unit

    • B. 

      Purge the reactor with nitrogen

    • C. 

      Change piping on top of reactor for burn-off

    • D. 

      Blind-off the reactor


  • 47. 
    1.       Elevation adjustments on the pipe hanger should be made at which point?
    • A. 

      A

    • B. 

      B

    • C. 

      C

    • D. 

      D


  • 48. 
    What should a boilermaker do to verify hydro-test pressure for exchangers?  
    • A. 

      Check the information plate or drawing

    • B. 

      Call the manufacturer or shipping company

    • C. 

      Check the standard operating procedures and the fire and safety guidelines

    • D. 

      Notify the control room operator


  • 49. 
    When performing a welding repair, you MUST have a copy of what on hand?  
    • A. 

      The welding procedure specification

    • B. 

      The quality assurance manual

    • C. 

      The contractor's insurance certificate

    • D. 

      The contractor's personnel records


  • 50. 
    If the hook is loaded off-center, the safe working load is__________  
    • A. 

      Decreased

    • B. 

      Increased

    • C. 

      Twice the rated capacity of the hook

    • D. 

      Not affected


  • 51. 
    Rigging is to be done with a wire choker over a beam.  When is a softener REQUIRED?  
    • A. 

      When the load is heavy

    • B. 

      At all times

    • C. 

      If the load is to be shifted

    • D. 

      If the steel edges are sharp


  • 52. 
    Why are there ball checks on sight-glass valves?  
    • A. 

      To allow easier filling within the sight-glass

    • B. 

      To stop the flow if there are leaks or if the sight-glass breaks

    • C. 

      To permit the sight-glass to be removed without interrupting the service

    • D. 

      To permit easy installation and removal of valves


  • 53. 
    MOST spring cans are made of what material?  
    • A. 

      Brass alloy

    • B. 

      Aluminum

    • C. 

      Copper

    • D. 

      Steel


  • 54. 
    What type of power tools should be selected for use in a no-spark producing areas?  
    • A. 

      Electric tools

    • B. 

      Pneumatic tools

    • C. 

      Battery-operated tools

    • D. 

      Gas powered tools


  • 55. 
    What problems are associated with tube rolling?  
    • A. 

      Tube materials is too hard

    • B. 

      Drum holes are serrated

    • C. 

      Air pressure is too high

    • D. 

      Improper expanding and depth


  • 56. 
    After blinding, what should a worker do before removing any flange bolts on the exchanger channel head?  
    • A. 

      Check the pressure guages, pull the dollar plate, and open the bleeder valve

    • B. 

      Pull the pressure guages, rod the bleeder valve to ensure they are open, and pull the dollar plate

    • C. 

      Rod the pressure guages, pull the dollar plate, and block open the bleeder valves

    • D. 

      Pull the pressure guages, pull the dollar plate and block the bleeder valve closed


  • 57. 
    What should be used to plug a tube at either end of a weld to prevent air circulation?  
    • A. 

      Bread

    • B. 

      Rag

    • C. 

      Duct tape

    • D. 

      Purge paper


  • 58. 
    The decimal equivalent of 56 inches is__________  
    • A. 

      4.50 feet

    • B. 

      4.67 feet

    • C. 

      4.80 feet

    • D. 

      5.60 feet


  • 59. 
    How are tapered plugs installed in the ends of a leaking tube in a typical exchange-tubing bundle?  
    • A. 

      The plugs are placed into the end of the tube at the tube sheet and hammered in with a sledge hammer

    • B. 

      The plugs are placed into the end of the tube at the channel cover and tack-welded

    • C. 

      The plugs are screwed into the tube and a mandrel is inserted in the plug

    • D. 

      The tube is threaded using a die set and the plugs are screwed into the tube


  • 60. 
    Why should an extra-thick blind be used for hydro-testing?  
    • A. 

      It prevents the pan-cake effect and provides easy removal

    • B. 

      The thickness of the blind will not have any effect

    • C. 

      It equalizes the pressure

    • D. 

      Frequent removal of the blind is not required


  • 61. 
    A reinforcement pad is used on the shell of a vessel to__________  
    • A. 

      Provide backing while the nozzles are being welded

    • B. 

      Provide anchor points for scaffold errection

    • C. 

      Strengthen nozzles and man-ways

    • D. 

      Correct elevation differences between the plates


  • 62. 
    A crane is being used to remove a valve from a run of pipe.  When should the rigging material be attached to the valve?  
    • A. 

      Before any bolts are removed from flanges

    • B. 

      Before the last bolt is removed from each flange

    • C. 

      After all the bolts are loosened on each flange

    • D. 

      After all the bolts are removed from one flange, but before removing any of the bolts on the other flange


  • 63. 
    Which type of flange REQUIRES a full-face gasket?  
    • A. 

      Raised-face

    • B. 

      Flat-face

    • C. 

      Ring joint

    • D. 

      Toungue and groove


  • 64. 
    Hoist or load attachment chains, wire rope slings and kooks should be visually inspected?  
    • A. 

      Before each use

    • B. 

      Daily

    • C. 

      Monthly

    • D. 

      Weekly


  • 65. 
    What type of gasket is usually used when a steam service drum is blinded?  
    • A. 

      Spiral-wound

    • B. 

      Teflon

    • C. 

      Gar-lock

    • D. 

      Neoprene


  • 66. 
    All of the following are parts of an exchanger EXCEPT?  
    • A. 

      A dollar plate

    • B. 

      A tube sheet

    • C. 

      Bubble caps

    • D. 

      A channel head


  • 67. 
    Who should a boilermaker consult about the correct hydro-test pressure on a piece of equipment?  
    • A. 

      Quality assurance

    • B. 

      Safety department

    • C. 

      General foreman

    • D. 

      Pipefitter


  • 68. 
    What size Flex italic gasket should be used on a 6-inch, 400# flange on an exchanger?  
    • A. 

      6-inch 150#

    • B. 

      6-inch 300#

    • C. 

      6-inch 400#

    • D. 

      6-inch 600#


  • 69. 
    Which of the following is a hazard of working with Kaowool insulation in furnaces?  
    • A. 

      Inhalation of ceramic insulation fibers

    • B. 

      Ingestion of insulation

    • C. 

      Sharp edge on insulation

    • D. 

      Fragile surface area


  • 70. 
    The acetylene pressure at the bottle of an oxy-acetylene cutting torch exceeds 15psi.  What might be the result?  
    • A. 

      The torch will cut more efficiently

    • B. 

      The acetylene could become unstable, and the acetylene bottle could explode

    • C. 

      The acetylene will not flow through the torch

    • D. 

      The acetylene could be wasted


  • 71. 
    What materials should be used to secure a socket to an impact wrench?  
    • A. 

      Retainer rings

    • B. 

      Tie-wraps

    • C. 

      Metal pin and tie wire

    • D. 

      Rope and metal pin


  • 72. 
    All the items listed below are the MOST common methods of determining pipe lengths EXCEPT  
    • A. 

      Face-to-face

    • B. 

      Center-to-center

    • C. 

      Center-to-face

    • D. 

      Center-to-end-of-line


  • 73. 
    What is the MOST commonly used light-lifting device?  
    • A. 

      Screw jack

    • B. 

      Chain hoist or chain fall

    • C. 

      Hydraulic jack

    • D. 

      Air tugger


  • 74. 
    What is the first thing a worker should do during a chemical release evacuation?  
    • A. 

      Check that no one is left inside

    • B. 

      Verify that sirens have not sounded for a drill

    • C. 

      Check wind direction

    • D. 

      Find the nearest stairwell


  • 75. 
    Why is stainless steel used for corrosive-type service?  
    • A. 

      It can be custom-shaped for bends

    • B. 

      It is more resistant to caustic-type material

    • C. 

      It is heavier than carbon

    • D. 

      It is lighter than aluminum


  • 76. 
    How should a packing gland on a gate valve be tightened down?  
    • A. 

      Tighten packing gland down evenly

    • B. 

      Tighten one side down, and then the other

    • C. 

      Tighten down by hand only

    • D. 

      Tighten packing gland down as hard as possible


  • 77. 
    Tubes in a furnace can be made of all of the following materials EXCEPT  
    • A. 

      Inconal

    • B. 

      Brass

    • C. 

      Monel

    • D. 

      Incalloy


  • 78. 
    What substance has a low resistance to solvent and oil?  
    • A. 

      Silicone

    • B. 

      Nitrile

    • C. 

      Neoprene

    • D. 

      Natural rubber


  • 79. 
    What size wrench should be used to blind an 8-inch, 150# flange?  
    • A. 

      15/16

    • B. 

      1 1/16

    • C. 

      1 1/4

    • D. 

      2 inches


  • 80. 
    Which one of the signals instructs the crane operator to "lower the load slowly"?
    • A. 

      A

    • B. 

      B

    • C. 

      C

    • D. 

      D


  • 81. 
    Why are lock-out/tag-out(s) used on valves, switches, and equipment?  
    • A. 

      To start up the operation

    • B. 

      To slow down the operation

    • C. 

      To check the operation

    • D. 

      To prevent the operation


  • 82. 
    Which fitting changes the centerline of a pipe system?  
    • A. 

      Concentric reducer

    • B. 

      Swedge valve

    • C. 

      Van stone flange

    • D. 

      Eccentric reducer


  • 83. 
    Trays are installed in a tower.  Why the internal man-ways are temporarily left out?  
    • A. 

      To ensure that no one is left inside

    • B. 

      To allow for re-tightening

    • C. 

      For final inspection

    • D. 

      For safety


  • 84. 
    Why should an extra thick blind be used when hydro-testing?  
    • A. 

      It prevents a pan-cake effect and provides for easy removal

    • B. 

      The thickness of the blind will not have any effect

    • C. 

      It equalizes the pressure

    • D. 

      Frequent removal of the blind is not required


  • 85. 
    What is another name for a wedge socket?  
    • A. 

      Clevis

    • B. 

      Becket

    • C. 

      Clip

    • D. 

      Impact


  • 86. 
    What letter represents the tub (bell) head?  
    • A. 

      A

    • B. 

      B

    • C. 

      C

    • D. 

      D


  • 87. 
    When an exchanger tube is plugged, why is the tube cut before the second plug is installed?  
    • A. 

      To pevent pressure build-up

    • B. 

      To stop flow through tube

    • C. 

      To prevent a hydraulic effect

    • D. 

      So that the plug can be driven deeper


  • 88. 
    Where would a rim plate be found?  
    • A. 

      Part of a floating roof

    • B. 

      The highest shell ring on the tank

    • C. 

      An exterior stabalizer around the base

    • D. 

      The perimeter row of deflector sheets


  • 89. 
    Why should a full port valve be used for a corrosion probe?  
    • A. 

      To ensure full penetration

    • B. 

      So the probe can be installed without hanging up

    • C. 

      So the probe will not corode the valve

    • D. 

      So the valve can be closed


  • 90. 
    How should spring can hangers be prepared prior to hydro-testing?  
    • A. 

      No special adjustments are necessary

    • B. 

      Put the travel stops in the spring

    • C. 

      Remove the travel stops and set the hanger

    • D. 

      Set the spring for test mode


  • 91. 
    What does “MWT” mean in reference to boiler tubing?  
    • A. 

      Min weight tested

    • B. 

      Min wall thickness

    • C. 

      Max weight tested

    • D. 

      Max wall thickness


  • 92. 
     How often MUST wire chokers be inspected?  
    • A. 

      Daily

    • B. 

      Weekly

    • C. 

      Monthly

    • D. 

      Before each use


  • 93. 
    What does “B.O.P.” stand for?  
    • A. 

      Both on plane

    • B. 

      Both on pipe

    • C. 

      Bottom of pipe

    • D. 

      Bottom of plane


  • 94. 
    The MOST commonly used wrench size for tray work is__________  
    • A. 

      7/16

    • B. 

      9/16

    • C. 

      3/4

    • D. 

      7/8


  • 95. 
    The welding reference line is ALWAYS read from__________
    • A. 

      Left to right

    • B. 

      Right to left

    • C. 

      Top to bottom

    • D. 

      Corner to corner


  • 96. 
    What protects the Kaowool insulation on the inside of radiant section walls?  
    • A. 

      Steel plate

    • B. 

      Fire bricks

    • C. 

      Steel rods

    • D. 

      Concrete


  • 97. 
    What is the difference between a 300# flange and a 150# flange?  
    • A. 

      A 300# flange weighs twice as much as a 150# flange

    • B. 

      A 300# flange is raised-faced and a 150# flange is flat-faced

    • C. 

      A 300# flange has twice as many bolts as a 150# flange

    • D. 

      A 300# flange has a different pressure rating than a 150# flange


  • 98. 
    A boilermaker removes radiant tubes from a furnace before making any cuts on the top or bottom of the furnace.  What should the boilermaker do next?  
    • A. 

      Tie off to the top of tubes

    • B. 

      Build scaffolds inside the fire box

    • C. 

      Pull any associated steam piping

    • D. 

      Pull all feed control valves


  • 99. 
     What size bolts are used in a 4”-150# flange?  
    • A. 

      5/8

    • B. 

      3/4

    • C. 

      1/2

    • D. 

      7/8


  • 100. 
    And a 3”-300# flange?  
    • A. 

      5/8

    • B. 

      3/4

    • C. 

      1/2

    • D. 

      7/8


  • 101. 
    What factor determines the degree a tray can be pre-assembled before installation into the tower?
    • A. 

      Hoist capacity

    • B. 

      Bulkhead location

    • C. 

      Man-way size

    • D. 

      Depth of the sump


  • 102. 
    What wrench size is used to tighten the nut on a 7/8 inch stud bolt?  
    • A. 

      7/8

    • B. 

      1 1/16

    • C. 

      1 1/4

    • D. 

      1 7/16


  • 103. 
    What is the proper way to break out a flange?  
    • A. 

      The easy bolts first

    • B. 

      Bottom bolts away from you

    • C. 

      Bolts on top of flange

    • D. 

      All the above okay


  • 104. 
     How many pipe wrenches are used to break a union?  
    • A. 

      1

    • B. 

      3

    • C. 

      0

    • D. 

      2


  • 105. 
    How many degrees are there in a tower that is 5-ft in diameter?  
    • A. 

      100

    • B. 

      150

    • C. 

      180

    • D. 

      190


  • 106. 
    Which of the following is not a tray?  
    • A. 

      Ballast cap

    • B. 

      Bubble cap

    • C. 

      Sieve

    • D. 

      Waffle


  • 107. 
    When installing a distributor, what must you check to assure it fuctions properly?
    • A. 

      The part number

    • B. 

      Level

    • C. 

      Direction of flow

    • D. 

      Head pressure


  • 108. 
    What tool is best used to remove tower internal attachments?  
    • A. 

      Chisel and hammer

    • B. 

      Porta-band saw

    • C. 

      Gouger

    • D. 

      Ring extractor


  • 109. 
    All tray towers have only one internal man-way per tray?  
    • A. 

      True

    • B. 

      False


  • 110. 
    When laying out for the installation of a nozzle, where can your measurement are verified from when available?  
    • A. 

      North and South orientation

    • B. 

      Hand book

    • C. 

      An existing nozzle

    • D. 

      Flow chart


  • 111. 
     Before rigging a load to be lifted, what do you need first?  
    • A. 

      A requisition form

    • B. 

      A flagman

    • C. 

      The weight

    • D. 

      A helper


  • 112. 
    If a nylon sling is frayed on just one edge, what can you do with it?  
    • A. 

      Use duct tape and cover that area

    • B. 

      Double it

    • C. 

      Use only with another good sling

    • D. 

      Red tag or cut it up


  • 113. 
    Before lifting a load, what should you attach to it?  
    • A. 

      A flag

    • B. 

      Wind sock

    • C. 

      Tag-line

    • D. 

      A sky hook


  • 114. 
     When lifting a load over-head, you should not interrupt the people working below? a.       True b.       False
    • A. 

      True

    • B. 

      False


  • 115. 
    Which atmospheric conditions can make it difficult to properly level support bars when re-traying a tower?  
    • A. 

      Humidity

    • B. 

      Clouds

    • C. 

      Rain

    • D. 

      Sun


  • 116. 
    Why are lock-out/tag-out used on valves, switches, and equipment?
    • A. 

      To start up operation

    • B. 

      To slow down operation

    • C. 

      To check the operation

    • D. 

      To prevent operation


  • 117. 
    What do operators use to manually check the level on equipment?
    • A. 

      Gate valve

    • B. 

      Sight glass

    • C. 

      Feed nozzle

    • D. 

      Vapor line


  • 118. 
    What is the purpose of the weirs in a tower?  
    • A. 

      They control the vapors going up the tower

    • B. 

      They control the flow of liquid on each tray level

    • C. 

      They allow liquids to overflow to the tray below

    • D. 

      They allow access through the cover


  • 119. 
    Why does an operator rod-out a bleed valve?  
    • A. 

      To see if the valve is working

    • B. 

      To ensure the line is clear

    • C. 

      To ensure the line is pressured up

    • D. 

      To see if the valve is within specs


  • 120. 
    Tubes in a furnace can be made of all the following materials EXCEPT  
    • A. 

      Inconel

    • B. 

      Brass

    • C. 

      Monel

    • D. 

      Incoloy


  • 121. 
    What is put on flange bolts before they are put back into the flange on a heat exchanger?  
    • A. 

      Never-seize lubricant

    • B. 

      Heavy weight motor oil

    • C. 

      WD-40

    • D. 

      Teflon


  • 122. 
    Which of the following tools are usually used to install trays in towers?  
    • A. 

      Pick, ratchet, channel locks

    • B. 

      Chipping gun, Phillips screwdriver, hammer wrench

    • C. 

      Flange spreader, 12-pound hammer, 1 1/8 combination wrench

    • D. 

      Needle sealer, torque wrench, torpedo level


  • 123. 
    What is a hammer wrench commonly used for/  
    • A. 

      Aligning flanges

    • B. 

      Breaking difficult bolts

    • C. 

      Chisel tray hardware

    • D. 

      Separating flanges


  • 124. 
    What is meant by the phrase “flush-nut”  
    • A. 

      A bolt reaches the outside edge of a nut

    • B. 

      A nut is off-colored

    • C. 

      A nut is rusted

    • D. 

      A nut has been killed


  • 125. 
    What type of gasket is normally used on flange valve in a high pressure/high temperature line?  
    • A. 

      Flexitallic spiral wound

    • B. 

      Garlock

    • C. 

      Neoprene rubber

    • D. 

      Permatex paper


  • 126. 
    How should a boilermaker determine the proper size gasket to install in a set of flanges?  
    • A. 

      Check the blueprint plan views

    • B. 

      Check the specifications

    • C. 

      Check the size and rating stamped on the flanges

    • D. 

      Check the equipment installation details


  • 127. 
    A boilermaker is blinding with spacers.  Where should the spacers be placed?  
    • A. 

      Between the gasket and the flange

    • B. 

      Between the gasket and the blind

    • C. 

      Between the gasket and the bolt

    • D. 

      The spacer are used as blinds


  • 128. 
    What protects the Kawool insulation on the inside of radiant section walls?  
    • A. 

      Steel plates

    • B. 

      Fire bricks

    • C. 

      Steel rods

    • D. 

      Concrete


  • 129. 
    1.       Demister pads can be found in which of the following locations? a.       Towers, drums, vessels b.       Exchangers, towers, boilers c.        Exchangers, vessels, drums d.       Control valves, gate valves, butterfly valves
    • A. 

      Towers, drums, vessels

    • B. 

      Exchanger, towers, boilers

    • C. 

      Exchanger, vessels, drums

    • D. 

      Control valves, gate valves, butterfly valves


  • 130. 
    What do the letters T.O.E. stand for?  
    • A. 

      Thread on end

    • B. 

      Taper one end

    • C. 

      Thread one end

    • D. 

      Top of elevation


  • 131. 
    What procedure does not need to be performed before a boilermaker enters a vessel?  
    • A. 

      Blinding the vessel

    • B. 

      Opening manways to the vessel

    • C. 

      Gas-freeing the vessel

    • D. 

      Removing demister pads


  • 132. 
    Which of the following characteristics of a gasket must be checked before the gasket is installed in a flange?  
    • A. 

      Color

    • B. 

      Width

    • C. 

      Length

    • D. 

      Material


  • 133. 
    1.       What are hydro-cups used to test? a.       Boiler systems b.       Single tubes c.        Tig rigs d.       Gas systems
    • A. 

      Boiler system

    • B. 

      Single tubes

    • C. 

      Tig rigs

    • D. 

      Gas system


  • 134. 
    How are air blowers that provide ventilation to a crew working in a tower normally set up?
    • A. 

      A blower is placed in the top man-way with air blowing in

    • B. 

      Bloweres are placed in the top and bottom man-way with the air blowing in

    • C. 

      A blower is placed in the bottom man-way with the air exhausting out

    • D. 

      A blower is placed in the top man-way with the air exhausting out


  • 135. 
    What should be inspected before bundles are installed in an exchanger shell?  
    • A. 

      Seating surfaces

    • B. 

      Burner assembly

    • C. 

      Shell

    • D. 

      Bolts


  • 136. 
    Why do steam systems incorporate low point drains and traps?  
    • A. 

      To remove extra steam

    • B. 

      To remove condensate

    • C. 

      To assist in hydro-testing

    • D. 

      To facilitate valve replacement


  • 137. 
    Which of the following is a hazard of working with a Kawool insulation in furnaces?  
    • A. 

      Ceramic insulation fibers

    • B. 

      Ingestion of insulation

    • C. 

      Sharp edge on insulation

    • D. 

      Fragile surface area


  • 138. 
    Any welding that is done on a reactor must be done by whom?  
    • A. 

      Boilermaker

    • B. 

      Tank welder

    • C. 

      Certified vessel welder

    • D. 

      Structural welder


  • 139. 
    Most spring cans are made of what material?  
    • A. 

      Brass alloy

    • B. 

      Aluminum

    • C. 

      Copper

    • D. 

      Steel


  • 140. 
    MSDS sheets and HAZCOM information are required to be kept on site in what location?  
    • A. 

      Control room

    • B. 

      Tool room

    • C. 

      Forman's gang-box

    • D. 

      Administrative office


  • 141. 
    What should a boilermaker do before performing a hydrostatic test?  
    • A. 

      Remove pressure relief valves

    • B. 

      Verify that all control mechanisms are left in place

    • C. 

      Verify that all orifice flanges are left in place

    • D. 

      Remove all bleeder valves


  • 142. 
    Which of the following connecting units are used on pipe hangers?  
    • A. 

      C-clamps, threaded rods, beam clips

    • B. 

      Turnbuckles, beam clips, c-clamps

    • C. 

      Eye bolts, turnbuckles, beam clamps

    • D. 

      Eye bolts, turn stalls, beam clips


  • 143. 
    A reactor is to be filled with catalyst.  What man-way must be installed first?  
    • A. 

      Top

    • B. 

      Middle

    • C. 

      Bottom

    • D. 

      Any man-way may be installed first


  • 144. 
    When should spring cans be adjusted?  
    • A. 

      When the line changes from out-of-service to in-serrvice

    • B. 

      When the line changes from in-service to hot

    • C. 

      When the pipe is demolished

    • D. 

      Spring cans are never adjusted


  • 145. 
    A furnace tube is being replaced.  The tubes should be sealed back with what MINIMUM distance?  
    • A. 

      3"

    • B. 

      2"

    • C. 

      1"

    • D. 

      0.5"


  • 146. 
    All of the following are major components of a tower EXCEPT  
    • A. 

      A mister pad

    • B. 

      Trays

    • C. 

      A relief valve

    • D. 

      A gate valve


  • 147. 
    What are banana wedges used for?  
    • A. 

      Shimming bundles

    • B. 

      Raising the shell on a pedestal

    • C. 

      Spreading flanges

    • D. 

      Lining up the plate


  • 148. 
    What type of nuts are used for threaded fasteners?  
    • A. 

      12-piont

    • B. 

      Acorn

    • C. 

      Hexagonal

    • D. 

      Machine


  • 149. 
    How would the plumb of the completed shell be checked using a plumb bob and string line?  
    • A. 

      Drop a plum bob on a string from the top of the shell plate to the tank floor at one or two locations

    • B. 

      Drop a plumb bob on a string from the top of the shell plate to the tank at four to eight locations around the tank

    • C. 

      Drop a plumb bob on a string from the bottom of the tank to the top of the shell at one or two locations

    • D. 

      Start at the zero degree mark and use a plumb bob and string to check the plumb at 180 and 360 degrees


  • 150. 
    What kind of electrodes are used for gouging?  
    • A. 

      Low/High

    • B. 

      P5

    • C. 

      Stainless

    • D. 

      Copper alloy


  • 151. 
    A boilermaker inspects a screen and finds a small hole.  What should the boilermaker do?  
    • A. 

      Discard the screen

    • B. 

      Reassemble without the screen

    • C. 

      Repair the screen

    • D. 

      Reinstall the screen since the hole is small


  • 152. 
    Which of the following must a boilermaker do when reassembling an exchanger?  
    • A. 

      Torque the bolts to 75#

    • B. 

      Make sure that the gaskets are aligned

    • C. 

      Make sure that the bell plate is on the channel head

    • D. 

      Make sure that the float head is put on backwards


  • 153. 
    What are bull pins used for?
    • A. 

      Holdiong a large gap between two pieces of steel

    • B. 

      Aligning the matching bolt holes in two pieces of steel pipe

    • C. 

      Splitting pieces of metal during erection

    • D. 

      Loosening the centerline of the plate


  • 154. 
    What size wrench should be used to blind an 8”, 150# flange?  
    • A. 

      15/16

    • B. 

      1 1/16

    • C. 

      1 1/4

    • D. 

      2


  • 155. 
    A boilermaker finds a stretched shackle. What should the boilermaker do?  
    • A. 

      Continue using the shackle

    • B. 

      Take the shackle out of service

    • C. 

      Take the shackle and fix it by hammering it closed

    • D. 

      Heat-treat the shackle with a torch


  • 156. 
    What dimensions does an elevation drawing show?  
    • A. 

      Height and width

    • B. 

      Depth and length

    • C. 

      Depth and width

    • D. 

      Length and width


  • 157. 
    What type of oil is used to drill a hole in a header or boiler pressure part?  
    • A. 

      No oil is used

    • B. 

      Light weight

    • C. 

      Heavy weight

    • D. 

      Any grade is permissible


  • 158. 
    What should a boilermaker do to verify hydro-test pressure for exchangers?  
    • A. 

      Check the information plate or drawing

    • B. 

      Call the manufacture or the shipping company

    • C. 

      Check the standard operating procedures and the fire and safety guidelines

    • D. 

      Notify the control room operators


  • 159. 
    What is the name of the procedure used to tighten flanges?
    • A. 

      Hot bolting

    • B. 

      Four bolting

    • C. 

      Cold cutting

    • D. 

      Six bolting


  • 160. 
    What information must a boilermaker know before blinding a tower?
    • A. 

      Pipe size

    • B. 

      Circumference of the tower

    • C. 

      Flange size

    • D. 

      Tower height


  • 161. 
    On a scale of 3/8” = 1ft, how many feed to 1 – ½” represent?  
    • A. 

      6ft

    • B. 

      3ft

    • C. 

      4ft

    • D. 

      1ft


  • 162. 
    Which of the following power tools is used to remove rough edges or burrs on steel?  
    • A. 

      A porta-band saw

    • B. 

      A 7-inch grinder

    • C. 

      A scaler

    • D. 

      A mandrel


  • 163. 
    What is used to remove broken threaded end of pipe, plugs, and fittings?  
    • A. 

      A pipe tap

    • B. 

      Pipe reamer

    • C. 

      Pipe cutter

    • D. 

      Pipe extractor


  • 164. 
    What is the first thing a boilermaker should do before opening a drum?  
    • A. 

      Verify that the drum is locked out anfd blinded

    • B. 

      Verify that the drum is open

    • C. 

      Verify that the drum is grounded

    • D. 

      Verify that the drum is pressurized


  • 165. 
    What holds the trays to the rings in a tower?
    • A. 

      Weir plates

    • B. 

      Downcomers

    • C. 

      Tray clips

    • D. 

      Chimneys


  • 166. 
    All of the following are permanent pipe supports EXCEPT
    • A. 

      Dummy legs

    • B. 

      Pipe shoes

    • C. 

      Spring cans

    • D. 

      Ss tie wires


  • 167. 
    What position should a relief valve be transported in?
    • A. 

      Horizontal

    • B. 

      Upside down

    • C. 

      Open

    • D. 

      Vertical


  • 168. 
    What type of tank has legs on the roof?
    • A. 

      Floating roof

    • B. 

      Fixed roof

    • C. 

      Pinned roof

    • D. 

      Short roof


  • 169. 
    A worker is installing a skillet blind in a flange for blanketing off the gas line to the burners. The appropriate gasket cannot be found. What should the worker do?
    • A. 

      Put the skillet blind in the flange and tighten the bolts. A gasket is not required for the test

    • B. 

      Do no continue installing the blind until the proper gasket is located. A gasket is required for the blinding of the gas line.

    • C. 

      Put a second blind in the flange to replace the gasket

    • D. 

      Make a gasket from any available material


  • 170. 
    Why does a boilermaker use a test tree that has a bleed valve when hydro-testing an exchanger?
    • A. 

      To relieve pressure on the exchanger

    • B. 

      To drain condensation

    • C. 

      So that the test pump can be disconnected

    • D. 

      So that air can be removed from the exchanger


  • 171. 
    Boiler code material can be found on all the following EXCEPT
    • A. 

      Boilers

    • B. 

      Furnaces

    • C. 

      Towers

    • D. 

      Spring cans


  • 172. 
    What substance has a low resistance to solvent and oil?
    • A. 

      Silicone

    • B. 

      Nitrile

    • C. 

      Neoprene

    • D. 

      Natural rubber


  • 173. 
    All of the following components of a floating head exchanger must be installed when a shell hydrotest is performed EXCEPT  
    • A. 

      A bell head

    • B. 

      A channel cover

    • C. 

      A channel head

    • D. 

      A floating head


  • 174. 
    Butterfly valves are most commonly used for what product system?
    • A. 

      Acid

    • B. 

      Hydrocarbon

    • C. 

      Steam

    • D. 

      Water


  • 175. 
    A boilermaker who is disassembling an exchanger should do which of the following?
    • A. 

      Make line-up marks on each piece

    • B. 

      Review old plans

    • C. 

      Make as builts

    • D. 

      Replace damaged parts


  • 176. 
    How are convection section tubes oriented?
    • A. 

      Vertically

    • B. 

      Horizontally

    • C. 

      On top of the furnance

    • D. 

      On the bottom of furnance


  • 177. 
    What can be done with a spectacle or figure eight blind?
    • A. 

      It can be used to blind two parallel lines at once

    • B. 

      It can be installed without spreading the flanges

    • C. 

      It can be rolled to block or permit flow

    • D. 

      It can be used to measure pipe flow


  • 178. 
    Which of the following is required when test blinds are installed?
    • A. 

      Packing

    • B. 

      Longer bolts

    • C. 

      Shorter bolts

    • D. 

      Stainless steel bolts


  • 179. 
    What is the standard hand signal that instructs a crane operator to raise the boom?
    • A. 

      Closed fist, thumb pointing downward

    • B. 

      Closed fist, thumb pointing skyward

    • C. 

      Open hand, index finger pointing downward

    • D. 

      Open hand, index finger pointing skyward


  • 180. 
    How should a packing gland on a gate valve be tightened down?
    • A. 

      Tighten packing gland down evenly

    • B. 

      Tighten one side down and then the other

    • C. 

      Tighten down by hand only

    • D. 

      Tighten packing gland down as hard as possible


  • 181. 
    A quality control person who is looking at a channel cover bolt-up should check all of the following EXCEPT
    • A. 

      The gasket surface

    • B. 

      The weld

    • C. 

      The thread engagement

    • D. 

      The gasket correctness


  • 182. 
    What are the valves in a piping system used for?
    • A. 

      They filter out debris from entering tower

    • B. 

      They support a long run of pipe

    • C. 

      They serve as spacers between open flanges

    • D. 

      They regulate flow and relieve pressure


  • 183. 
    Where sould a safety harness be secured when work is performed on a suspended scaffold?
    • A. 

      Cable lift

    • B. 

      Cable lift suspension rope

    • C. 

      Rigid structure

    • D. 

      Guardrail


  • 184. 
    An exchanger is being hydro-tesed. Where should the vent be located?
    • A. 

      Bottom of exchanger

    • B. 

      Middle of exchanger

    • C. 

      Top of exchanger

    • D. 

      Next to the relief valve


  • 185. 
    Where should a high point bleed be installed for a 2" hydro-test?
    • A. 

      Down low on the bottom of the vessel

    • B. 

      In the middle of the vessel

    • C. 

      On the highest point above water level

    • D. 

      Next to the test header


  • 186. 
    What is the purpose of a relief valve?
    • A. 

      Maintain a safe operating level

    • B. 

      Regulates steam pressure

    • C. 

      Regulates air pressure

    • D. 

      Relieve excess air flow


  • 187. 
    All of the following are parts of an exchanger EXCEPT
    • A. 

      A dollar plate

    • B. 

      A tube sheet

    • C. 

      Bubble caps

    • D. 

      A channel head


  • 188. 
    Who must be contacted before boiler code material can be removed?
    • A. 

      General foreman

    • B. 

      Q.C. department

    • C. 

      Fire and safety specialist

    • D. 

      Operations


  • 189. 
    What is the O.D. of the gasket required for an 8"-150# RF flange?
    • A. 

      10"

    • B. 

      11'

    • C. 

      12"

    • D. 

      13"


  • 190. 
    What type of construction uses two spaced tube sheets at one or both ends of a heat exchanger?
    • A. 

      Baffle

    • B. 

      Tube sheet alignment

    • C. 

      Single tube sheet

    • D. 

      Double tube sheet


  • 191. 
    In a U-Tube bundle exchanger, what protects tubes from excessive wear under shell inlets?
    • A. 

      Dollar plate

    • B. 

      Demister pad

    • C. 

      Key plate

    • D. 

      Splash plate


  • 192. 
    When may personnel lifts be moved in the fully extended position?
    • A. 

      Any time that the lift needs to be relocated

    • B. 

      Only outside of normal working hours

    • C. 

      Not under any conditions

    • D. 

      Only when a full crew is present


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