AKRAMANUJAN.

ORG
23rd JANUARY 2020
FUNCTION 4(41)
ramanujan1933@gmail.com

NOTE:- I am once again repeating the request for questions

from other centres so that it helps you all in preparing for
the orals. you can send hand written scanned sheets of
questions to my e-mail given at the head. Please treat this
as urgent.

since i am not receiving questions from

students I have started a series of questions based
on sketching, which some examiners are fond of
asking. the sketches exhibited here are easy to draw
and must be practiced. these questions will be
given for all functions. This series was started from
blog 233 and will now continue in the function 4
series.
QUESTIONS COMPOSED BY AKR

27 Illustrate the following defects by a suitable sketch and

suggest suitable repairs

1 necked or wasted stays. What is the cause for

wastage.

Answer:- wastage is caused by acidic corrosion due to lack of

treatment.

Necked and wasted stays which have wasted more than 25%
of its cross section area are to be renewed completely and
attaché in the same manner as they were originally attached,
which means if they were screwed in and fitted with check
nuts , the same method of fixture should be adopted for the
renewed stays. If they are welded to the plating, the renewed
stays should be similarly welded.

2 external corrosion of mounting bottom flange what is the

cause.

Answer :- The cause is continuous leakage from leaky joints

or glands leading to air corrosion.

The wasted shell plating around the mounting is suitably built

up by welding using a compatible electrode, as recommended by
the class surveyor. The welding has to be done by a class
approved welder with the recommended preheat, and ground
smooth. The corrective action suggested should be done when
the residual thickness is not less than 75% of original thickness.
3 caustic embrittlrment cracks.

Answer:- Caused by excessive reseve alkalinity in the water.

Caustic embrittlement is exhibited as cracks radiating

outwards around tube ends on the tube plate in boilers
where alkalinity levels are maintained high and the boilers
are being forced and work at variable pressures. These
cracks can also occur around leaky manhole fittings.
The repair is to crop the affected part and
renew with a new insert. It may be mentioned here that
this defect will not occur in boilers where alkalinity reserve
is maintained at a moderate level.

4 grooving cracks

Answer:- Grooving is exhibited by hair line cracks which are

not continuous occurring at the curvature of flanged
connections. In vertical boilers it occurs all around on the inner
side of the Ogee ring and the curved surfaces of the smoke box
. In cylindrical boilers it occurs on the flanged connection of
the end plate. Grooving is caused by the flexing action of the
curved surfaces and occurs by forcing the boiler when raising
steam. The hairline cracks are removed completely by using a
disc grinder till the cracks are removed completely. The grooves
are then filled up by welding using compatible electrodes and
with the service of the class approved welder.
5 corrosion cracks

Answer:- The cracks should be confirmed by carrying out

dye-penetrant test and if confirmed the cracks should be
gouged out, edges prepared and rewelded using compatible
electrodes by class approved welder.

6 Tube end leakage

Answer;- The tubes are cut and removed in the usual

way. After removing the tube stubs completely, the tube
ends on the plate are built up by welding using compatible
electrodes and carried out by class approved welder. The
tube ends are reamed using a standard size reamer to
remove the extra metal deposited. The new tubes are then
fitted in the method stated earlier.