100+ Free Special Equipment Inspector Practice Questions

special-equipment-law-and-tsg-standards

Statutory legal framework and technical safety standards governing special equipment inspection in China: the PRC Special Equipment Safety Law, TSG Z8002 inspection-personnel rules, TSG 21 pressure-vessel rules, TSG 11 boiler rules, TSG T7001 elevator inspection rules, and TSG 51 lifting-machinery rules. It covers equipment life-cycle responsibilities, reporting of serious hazards, and the three inspection-personnel levels: Inspector (检验员), Inspection Engineer (检验师), and Senior Inspection Engineer (高级检验师). TSG Z8001 NDT personnel are a separate qualification even though NDT principles are relevant inspection knowledge.

nondestructive-testing-methods

Principles, physics, equipment calibration, and defect identification for non-destructive testing under NB/T 47013 / GB/T 4730 (承压设备无损检测): Radiographic Testing (RT - X-ray tubes, gamma-ray isotopic sources Ir-192/Co-60/Se-75, radiation attenuation half-value layer HVL calculations, radiographic film systems Class T1-T4, optical density requirements D >= 2.0 / 2.3, wire image quality indicators IQI sensitivity, geometric unsharpness Ug = d * b / a, identification of weld defects including cracks, lack of fusion, incomplete penetration, porosity, and slag inclusions, radiographic defect grading I-IV); Ultrasonic Testing (UT - piezoelectric effect, longitudinal and transverse shear waves, acoustic velocity, acoustic impedance Z = rho * c, reflection/transmission coefficients, near-field distance N = D^2 / (4 * lambda), beam divergence angle, angle beam shear wave probes and K-values K = tan theta, DAC distance-amplitude curves with evaluation/sizing/rejection lines, defect sizing by 6 dB / 12 dB drop methods, Time of Flight Diffraction TOFD diffraction physics and dead zone analysis, Phased Array Ultrasonic Testing PAUT electronic beam forming and sectorial scanning); Magnetic Particle Testing (MT - ferromagnetic materials, magnetic domains, magnetic field leakage, continuous vs residual method, dry powder vs wet magnetic suspension, fluorescent vs non-fluorescent particles, UV-A black light intensity >= 1000 uW/cm^2, AC/DC electromagnetic yokes, cross yoke rotating magnetic field, standard sensitivity test pieces A1-30/100 and D-type); Liquid Penetrant Testing (PT - capillary action, surface wetting, contact angle, fluorescent vs visible dye penetrants, water washable vs solvent removable, dwell times >= 10 minutes, drying controls, non-aqueous wet developer application, development time 10-30 minutes); and Visual Testing (VT - direct visual, borescopes, videoscopes, illumination >= 500 lx, viewing angle >= 30 degrees, viewing distance <= 600 mm).

equipment-inspection-procedures-and-testing

Specific statutory inspection procedures, mechanical measurements, and proof tests across pressure and electromechanical equipment: Boilers (internal inspection every 2 years, external inspection annually, hydrostatic test every 6 years; steam drum, waterwall tubes, superheater/reheater header inspection, scale thickness evaluation, dual water level gauge independence, safety valve set pressure calibration and popping overpressure limits <= 10%); Stationary Pressure Vessels (wall thickness ultrasonic mapping, corrosion rate calculation CR = (t_initial - t_actual) / t_years, remaining service life estimation, hydrostatic proof test pressure PT = 1.25 * P * [sigma]/[sigma]t, pneumatic proof test pressure PT = 1.15 * P * [sigma]/[sigma]t, holding time >= 30 minutes, austenitic stainless steel hydrostatic test water chloride ion limit <= 25 mg/L, safety valve calibration interval 1 year, bursting disc burst pressure tolerance); Pressure Piping (industrial piping inspection cycles, wall thickness thinning, flange leakage, spring hanger displacement); Elevators (traction wire rope wear limit: diameter reduction > 10% or broken wire concentration, progressive safety gear for v > 0.63 m/s, overspeed governor calibration every 2 years, brake deceleration test 0.2g to 1.0g, buffer stroke, door lock bypass interlock); Lifting Machinery / Cranes (annual inspection for tower cranes and molten metal cranes, 2-year cycle for general overhead/gantry cranes, overload limiter setting tripping at 105%-110% of rated capacity, hook dangerous section wear limit >= 10%, hook opening deformation increase >= 15%, prohibition of hook repair welding, wire rope discard criteria).

defect-evaluation-and-risk-assessment

Engineering critical assessment (ECA), damage mechanism characterization, risk quantification, and statutory reporting: Stress corrosion cracking (SCC) mechanisms (austenitic stainless steel in chloride environments, carbon steel in wet H2S / caustic soda, branching transgranular/intergranular morphologies); Hydrogen damage mechanisms (hydrogen blistering, hydrogen-induced cracking HIC, sulfide stress corrosion cracking SSCC, high-temperature hydrogen attack HTHA); High-temperature creep damage in superheater/reheater steam lines (cavity formation on grain boundaries, micro-crack coalescence, pearlite spheroidization, Larson-Miller parameter); Mechanical and thermal fatigue (cyclic stress, beach marks, stress concentration at weld toes); Minimum allowable wall thickness evaluation using thin-walled cylinder formulas (t_min = (P * Di) / (2 * [sigma] * phi - P) + C); Risk-Based Inspection (RBI) methodology per GB/T 26610 (Probability of Failure PoF and Consequence of Failure CoF matrix, risk ranking, dynamic inspection interval adjustment); and Inspector Statutory Emergency Duties: immediate written notification to user unit and immediate statutory reporting to the local market supervision administration upon discovering serious accident hazards (严重事故隐患) or illegal operation.