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These 10 free AI questions are organized by exam domain, so you can see how each part of the National Board Authorized Inspector Commission (AI) blueprint is tested. Reveal the answer and explanation under each question.
By purchase order, an outside engineering firm accepts liability for errors in the design calculations it supplies to a vessel Manufacturer. The AI discovers that a specified nozzle load was omitted. Under the construction Code, which party still bears responsibility for ensuring that the completed vessel design complies?
Correct answer: A - The vessel Manufacturer.
An electrically heated boiler will supply process water at 145 psig and an outlet temperature of 270°F. No steam is delivered. Which construction classification applies to these specified service conditions?
Correct answer: A - Section I: a high-temperature-water boiler because the outlet exceeds 250°F.
On the approved Code-boundary drawing, a steam-piping spool lies within the boiler external piping of a Section I power boiler. The inspection plan must identify both its technical construction rules and its certification requirements. How should those responsibilities be assigned?
Correct answer: A - B31.1 supplies the technical construction rules; Section I retains inspection and certification jurisdiction.
A Type 1 longitudinal butt joint in a Section VIII, Division 1 shell has passed the specified UW-11(b) spot radiography, but the shell calculation uses E = 1.00. No service, material, or thickness rule requires full radiography. To retain the agreed examination plan, what should the AI require in the design review?
Correct answer: C - Use E = 0.85 and verify the shell thickness with the revised calculation.
A cylindrical shell has P = 300 psi, corroded inside radius R = 24.0 in., allowable stress S = 20,000 psi, and joint efficiency E = 0.85. Its internal corrosion allowance is 0.125 in. For the controlling hoop-stress check, use t = PR/(SE - 0.6P), where t excludes corrosion allowance. The minimum measured thickness after forming is 0.580 in. All other design and fabrication checks are satisfactory. Which thickness assessment is correct?
Correct answer: D - Accept: the required finished thickness is approximately 0.553 in.
Four shell blanks carry coded marks rather than the plate mill's original heat-number stamp. The marks were applied before cutting under an identification system accepted by the AI. Each code has a verified link through the cutting plan to the original plate and its matching material test report. On the question of material identification, the AI should:
Correct answer: B - Accept the coded marks and their verified records as material identification.
A welding procedure qualified without notch-toughness testing is proposed for a new vessel whose procedure must be impact-qualified. The process and base-metal combination are unchanged. The existing PQR records tensile and bend results, but no impact results; the original coupon is no longer available. Before issuing the WPS for this job, the welding engineer needs to:
Correct answer: C - Qualify a procedure with the required impact tests and supplementary essential variable controls.
After grinding a repair excavation in a nonferromagnetic austenitic stainless-steel head, a technician reports a negative magnetic particle examination. A fine surface-breaking crack is still suspected. The repair procedure permits an appropriate surface method. Which examination is best suited to check the excavation for the remaining crack?
Correct answer: D - Liquid penetrant examination of the cleaned, dry excavation.
During the staged pneumatic test of a new pressure vessel, a hissing leak develops at a bolted test closure. The vessel is still pressurized, and a fitter starts toward the closure with a wrench. Remote isolation and controlled venting are available outside the barricade. What is the immediate priority?
Correct answer: B - Keep personnel clear, isolate the gas supply, and depressurize remotely before intervention.
During an as-found calibration, a 0-300 psi working gauge gives reference/indicated readings of 60/62, 150/149, and 240/242 psi. The controlled procedure allows ±1% of full scale at each point; its measurement-uncertainty rule and all other checks are satisfied. A technician flags the first point because its error exceeds 1% of the reference reading. What disposition follows from the specified tolerance?
Correct answer: C - Accept without adjustment; each error is within ±3 psi.
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