Page3 EXERCISE NO. 1 FAILURE SAMPLES 4.) This is part of a 75 DN carbon steel boiler tube which was replaced, Please examine the sample and report briefiy: the defects present?; and the probable failure mode; and the possible cause(s) of failure; and how could this fallure be prevented practically by inspection. (3 marks) iN) Woloe Ddookma te-P uncle ooh a pRoyeuk = Soot bower adorn & Ta Ginel aighmads ‘.b) Please examine the 30DN tee connection in a carbon steel piping and report briefiy: i) the defects present; and il) the probable failure mode; and ii) «the possible cause(s) of failure; and iv) the minimum remaining thickness; and V) how could this failure be prevented practically by inspection. (8 marks) 1) Conrkeing “in heat-offected gore | 2) Haz cl callin, / sheas$ cokes ion. ceack ac, =’) Wansinse d Aaland steadile sulphides “we. eevee elsh, a Ena Yaad is Ohm aS cmek has pontledadthen , Magner bape Test_peot ‘s putts juke“ Ssahice 1..c) Please examine the 40 DN carbon steel economiser tube tube and report briefly: the defects present; and il) the probable failure mode; and ill) the possible cause(s) of failure, and iv) how could this failure be prevented prattically by inspection QQ: Tuning Infgenollle, “n) Seas 0S 1824 oR Hig vd Li fea dele ola) ae i (8 marks)Page 4 EXERCISE NO. 2 JOINT DETAILS Fig 1. Shall & Tbe Heat Exchanger ‘The sketch above shows a heat exchanger constructed from carbon steel, which has a shell 18 mm thick end tube plates 40 mm thick. Disregarding the vessel class and contents, sketch and give approximate dimensions of the folowing four joints b), c), e) and. 2.a) A typical preparation and weld for the shell to tube plate welded joint i.e. (b) in Figure 1 ° (2mark) TX GoTo Lpeirg 0-Fimn . y ke RF Tupesert ql a Ny pete 1.53mi Ge? top Net yy Scene,Page 7 3.c) Write results and brief recommendations (not a full report, but as dot points) to the owner on Specimen 3A (2 marks) — Kasolts : Shan are Fowl att_tep a domm lo ESmm wide “eit Pet aad fire ay ah guar a 3.2mm ComfeN = eombtnd Buea, 7 Ylin ake to @onu red Gujaise pkocadueo 3.d) What different actions would you have taken if the material of Specimen 3a-2 was nickel- bronze? (mark) E al & Tadeo Ma acall Weclyalise wid MVE compleed Nidal Banap & hg at moesS 0. Soe Eton pate 3 qe Kieu thockuass Exercise No. 4 Chat. wilds Re Racegiisad Yas Tm tustealia, Sandee) (On behalf of the vessel owner, you have requested radiograph from a new RT organisation, on a weld (see deteils below) which you have visually inspected and suspect may have internal defects which could affect the thermal fatigue performance of a process vessel. This is based the vessel maker's report of some cracking in this location on similar vessels. You are now supplied with the radiograph and the radiographer's report (se2 page 19) so that You can determine the acceptability of the weld and vessel, You are expected to review the radiograph but the RT organisation is responsible for its detalled interpretation of the radiograph. Vessel Wéld: Longitudinal SAW Double V butt weld in the shell near a support The shell is 20 mm thick carbon steel. 4.2) Please review the radiograph and the RT report. Make any working notes you require. (Pleese handle film only on edges and do not overheat.) All OL cites com ha sean hoes * Eeabela f Agiestic bua og Bal Wopleoe chek, ake pie sino, dalod? € handling —lopath Isle lida delet dit “aha at (east Heninlong 6 Elsflocdel amity golnm [bug 26-"97 —— eh mI Inka Viewer vseck, ; ee eee dy ae Sa 8Page 8 THEN MOVE TO YOUR DESK TO ANSWER THE REMAINING PARTS OF THIS EXERCISE — 4.) Indicate if items merked with * on the RT report (page 19) are acceptable or not to you, and briefly give the main reasons. (8 marks) 5. hase, Lducifice aga net (ecakek on He ead neh — Net _accottel . 43. Makiead grade need nat aipfato® ow Redueqtarhs 14 LQ) claaky is'tecd. & abjaues te be on Film sido, Thunhost wire “pet le‘sottide “Net Accoplebllé | C i9\ shelllaseey 1545037 Clasil — 1S Ho coneuct ode g class fe vse — Aecoptaalle. ee ve. Danshy jdesor honk T took weer amor y.u— Wedl wéhin Limnks Sm Aecopfelele EOL AF cold see ond oR wD bol jp anyeaie. needs toe bo weld to Jaw fal ie Le lorands of Haves Rave t — Net cept — 4.c) Indicate any other areas where tHe report or radiograph are not acceptable to you, and briefly give the main reasons. (2marks) = Tilieprdaher : vee io ow dbilievs dobact at jekst tbomm lena tat is het Riedell me oe eh. A X wold hie PB : Lo vessdl & nod! naads ts lee shut dloes y e~ a cstly 2xegdse , @ a dawceg fp te / peomeky & enviesnmront hile eovipmet"s Inve . Ads 1s bet W endicogaph fo subart uel prenss bot eather “mips Re-tfeecss tescecaitly PeeplEM 4.d) Indicate whether the weld is acceptable or not. (1 mark) ee has dolects well while the finws set oot (oy | asees7-99 orl 1S of a capable iinPage 9 4.¢) Briefly, indicate the main advice you would give the vessel owner regarding what action should be taken (3 marks) — ho Wadl eds © le shot dean as Seon aS ods bly ap. & fe eee aie lag dnl gale to tle lool & We of Uofaabees # pol pssst damage. to Boa Med Ie ontigonnat = De Seat (iene perce hel fsbo iv pleco. EXERGISE NO. 5 ‘As an independent inspector you are requested by a factory manager to urgently éarry out @ periodic inspection for the first time to show that the exhibited vessel is ‘safe” for continued service. Vessel details are: © Manufactured in 1985, installed in 1987 (see nameplate); * Located outside a building at a chemical process plant; © Reported to normally store compressed instrument air supplied by @ compressor at 1,0 MPa and 50°C max; (ol lubricated compressor), © Assume the volume is 200L and any defects are assessed by AS/NZS 3788 (Appendix W tor dents): The vessel interior is safe to examine; * No manufacturer's data report or previous inspection documents are available. Notes: Applicants are requested not to remove any sticker from the vessel. For the sake of the exercise the vessel is bolted to the floor and is not to be moved. For the purpose of this exercise, it can be assumed that the vessel can be pressurised by the hypothetical air compressor and other fittings (not installed). Extracts from AS/NZS 3788, AS 4343 and National Standard for Plant are attached to assist in answers.Page 10 5.2) Inspect the exhibited vessel; and record with a sketch the necessary observations as working notes you would normally take - assume your camera is not working. The safety valve may be removed if desired. (Maximum 18 minutes) (7 marks) Reno Plde Doole 7 Wenfictvne y = | As !2\0-77_ claw’ S pei MWe me oo || TPS Wife. Inala 8785 | 4. ota SIS _11234S° : I gt he SE | D ———— dest Count) 2 beng 2 Fomin afeond vessel. oth pa_dla cokestiwn ups Agofe aus 6 pilbeg Ole Me 2 Fancd tn abgags Gado ll. sumetoos soys Suppers 8 OK e : Tilkienls = Vowel , pull cvegession aermnd wilds elves Fagen PSV, No paessum gave. dkain whe wassing 7 NOL ovllut uallies muissinds ay eRkesion.” As poe Vsketel aber x Dok e+ = “ J ese SIT npeessacaad , sxolecl @ clativcl TO \pdieeo tnSpackin~ THEN MOVE TO YOUR DESK TO ANSWER THE REMAINING PARTS OF THIS EXERCISEPage 11 8.b) Write your final formal report to the owner and include advice on any need for registration of the design and vessel to satisfy the National Standard for Plant (Schedule 1 attachment 10). GQuwie . ABE Addevss Lecakious § Elon 2 AdMeda xxx Ens __befG sch phir JI! Plex & Nemoteg: AS par paeleos Pe ets “Trsplled AS pad! pans colts LAS bab pMliews pabell and Net! Fit far sevice Kicermponthohos - Rglace P50 wife Recoininucadl (ype (S marks) he fons. Yast nade Be td aot Challis Fake feel ada anoals Ww ait 3 ape. thal tho Shak dees a Risk asiaspuond £ bs bu: is te tyspackns plo les fa dl Cen tase Baya” cipbingnk aot &.c) + What parts of the safety valve did you check and how? * What else relating to the safely vaive would you do if the exhibited vessel was fully quipped with Moe a vaives etc? (3 marks) Chockad “Toa. : ci Me SehSbig Vollve » CRM el cakes stom : Dpetarion F easing qeak, TH veal (wos. edoipead “4 Bae To oferATE, Hon T Weald isthness Utd bp, passueiyehun @ tem uso. easiur opt "fo sue. iP Pav 1s wegPar We et pak Ae WD ge Nctaxe ee Tork a AOL Neer 4 aee 1D 10 Page 12 LID TD 5.d) If both the dlameter and length ofthis 200L vessel were increased by afactor often: 2807 °°°# @ What addliticftal examinations would you have made during this inspection? (2 marks) (It is not necessary to know the actual diameter or length) \nspaclina | Sopemeks, necosd to ula “051 “Capaislsh x ESV, _Iacrcnsedl thicknsses if shall , (i) Calculate the new pV value and comment on the type and frequency of future Assorne Antes E digg 2m length x Seo mm diamadeg oe N= Mrs Aastine 25°20 x | eso baeos = 3z,c00T x FeasseeaGmee) Table 62_150343-06 = 343,090 mal _Conkends = NAG Caie- empessal) ooo Lal = B Pe Riedie Lnspoction. to Yale y.1 3789 15.4 EXERCISE NO 6 INSPECTION USING MIRROR Please visually examine the inside of the vessel erid and opening of Specimen’ 6(@) for all significant signs using the mirror and torch for internal examination. 6.a) Record your sheers. (3 marks) rack LAT Teahicad, cmacks (4 foond FY) wich a — f (7 Tostftlo _nseshe faahng fe migaeke “ike thee kanal LL D 6.b) What “failure mode" is indicated by the defects? (1 mark) Fetiove ceacks Row, calc \eacks (Beth pense. S 4 ujasckal ty talons feapg be Rg dlalene gags") camany 6.c) Suggest ie reine causes of essere and failure. (2 marks) Conse the ereinal: mewactugina pe Bok, (aE deep _wsftlos ~ aa! hao eHih nic dveinsl the "Bee pecss & ‘thos creating teods Ralsoks :Page 13 6.) _ Indicate whether the end is acceptable or not, and why. (1 mark) EXERCISE NO7 INTER-CONNECTED BOILER INSPECTION You are required to inspect urgently for your first time the inside of a fire tube boiler No 1 in a boiler house at a food plant. The Chief Engineer shows you his rough sketches (P & ID and Cross Section) shown page 15, and indicates the boiler is open and ready for you to inspect. 7.) List the essential actions you would take immediately before entering the boiler; and give your reasons for each, (6 marks)Page 14" 7.b) List 6 positions where you would focus your inspection of boiler pressure parts, (exelucin s and fittings) and what you would look for: (@ marks) POSITION OBSERVATION 7.0) Indicate whether the type of failure in Specimen 7b) could ocour in this boiler, and aive reasons for your answer. (2 marks)Page 15 [Bomn Seen Refeviv * ai wth ore Qe Leg s@ "a. :§ sw i Benen org b) Boller Cross-Section : eePage 16 EXERCISE NO. 8 As part of your inspection of the total installation of a series of jacketed pans you have observed the arrangement below. ‘The pans have been shown to be acceptable to you. Indicate briefly the advice you would-give the owner in regard to the piping and overall arrangement. (7 marks) 1000KPa 2 200mD Pressure TO GENERAL SERVICE Redooing Boiler Valve me 80mmD po Pressure Reducing Valve. phe eh “Ta Condensate Retum to : = a s0mmD “he JACK] JACKETED JACKETED PAN yb PAN PAN pp 40bkPa DP 400 ke DP 250 kPa nelas s lo a ins _ pros ait Ridwoting Valves obs pas lino They ake “yn so pRssuee \s_ivadvegtetly cod at FooRgPage 17 EXERCISE.NO9 DENT INSPECTION 9.a) Measure and record the maximum depth and extent of the dent in the exhibited Specimen 9a, which represents the outer surface of a 40. mm thick vessel in carbon steel, “ (xia 45 minutes) (3 mae) tRonsleRal £ beassuerse-diam Jo mpm i Zz S withing Tako eee = Tow J ¢ we waite Puinie SiitZ Ze Aran Gon, ZA} (Le i oe = [eee ete nde: dash. we i eras Weoraticall — feomserse diam d dap Fox mim idanageut Othe rat Levnadtedind), diam SoA, 0 K12 prin 9.b) THEN MOVE TO YOUR DESK and comment on its acceptability to ASINZS3788 Appendix W. (Data rales (4marks) Lyprodix. eur dawks of ‘to _s50 min maa “dion & Bs dots i i shell * 250, mba dam & ho d doptl. Peau eet Wek 225 mia Lowaitls if ah chink assem Gly dill man dan HS bleh 2m = foul Vdatt is ae “Lon taiwan Tiainak = Des wt comply =P Astowe_ wee wild + Acted darth 1m pm) Is 9g £ the allewaedl dosti Crain 6 xloo ") = % min —7 Bte..Neot Compl 9.0) Provide £3 dot point ea at de main points. {2 marks) Seer ; —> Ra ash dot \s Ruler iho UH / = Dats vst dm ply fe Gee Wl Aes Sb { Dbpese 3 Din’ such a way hot { ~ it dees rit prsota. 2 fe pacha ree SMVGshinor = EK comnat Le vied egal in an! sbiiovs monhaR. Gr Wee esky Fee neto { Actetante Cyt - ‘Page 18 EXERCISE NO 10 WELD INSPECTION During commisstoning inspection of a large 85 mm thick carbon steel vessel prior to erection, you sight a welded joint represented by the external surface of Specimen 10a [This is part of a 8D replica taken directly from @ nozzle on a power station boller drum]. Note: The full thickness of the shell is 60 mm and the nozzle thickness is 20 mm, 10.2) Please indicate: (the estimated maximum depth of the “underflushing’ at the weld toes; and (i) how did the under-flushing ocour; and (3 marks) (ii) any other imperfections in the weld, ‘10.b) Assuming the specimen is the surface of @ low temperature nozzle eubject to fatigue indicate: ') whether you would accept or reject the welded joint; and i) give your reasons (2 marks) erected in Darwin, indicate: (whether you would accept or reject the welded joint, and 10. c) Assuming the weld represents the attachment of a lifting trunnion to the vessel being | (i) give your reasons (2'marks) |