SOPHOS ENGINEER EXAM SCRIPT 2026
COMPLETE QUESTIONS AND ANSWERS
◉ List 3 scale forming compounds found in feedwater and indicate if
it forms insoluble, scale, hard scale, or sludge and soft scale. Answer:
1. Calcium Sulphate- forms insoluble scale
2. Calcium Carbonate- forms sludge and soft scale
3. Calcium Silicate- forms hard scale
4. Magnesium carbonate- forms sludge and soft scale
5. Silica- forms hard scale
◉ Does a reheater on a boiler require a safety valve. Answer: Yes
The re-heater safety valve(s) must be capable of relieving all the
steam the re-heater can generate. At least 15% of the required
capacity shall be placed on the re-heater outlet.
◉ A flue gas analysis showed the following percentages by volume:
CO2= 15%, oxgen=5%. What is the excess air based on the
readings?. Answer: Excess Air= Oxygen by volume/ CO2 by volume =
5/15= 33.33%
,◉ What is the difference between active and inactive pitting?.
Answer: pustules/blisters having a brown oxide covering for over
the put, and then active are filled with black oxide of iron
◉ How are small turbine shafts aligned to a boiler feed pump shaft
and how do you check for shaft alignment?. Answer: The central
relation of the two shafts may be checked by placing a straight edge
parrell to the two shafts across the rims of the coupling flanges. This
check should be applied at four places about the flanges. The Parrell
relation of the two shafts can be checked measuring the distance
between the coupling flange faces with a feeler gauge. if there two
shafts are Parrell, these measurements will be equal at all points on
the coupling. also, a dial indicator can be used.
◉ Explain the results of using steam at a lower superheat
temperature than the turbine is designed for.. Answer: There will be
a loss of power and efficiency in the turbine because there will be
less total heat in the steam in the later stages.
There will also be an increase in corrosion and erosion in the blades
in the later stages due to this increased moisture content in the
steam.
◉ Mass general law Chapter 146 section 45A, when do refrigeration
and air conditioning systems need to be inspected?. Answer: 20 tons
or over if not used exclusively for agricultural, horticultural, or
,floricultural purposes or under the jurisdiction of the US
government.
◉ If the PH of boiler water is increased from 9 to 11, how many
times more basic is the water?. Answer: 100 times
◉ Considering pressure and temperature conditions, when shall a
boiler be built in accordance with the rules in the Power Boiler
Section I of the ASME Code?. Answer: When pressure exceeds 15 PSI
for a steam boiler or 160 psi and/or 250-degree F for a water boiler
◉ What is meant by reinforcement of a weld?. Answer: The amount
of weld above the surface of the plate on the face side. This ensures
full penetration for full thickness of plates to be joined.
◉ A. What is meant by a nondestructive test of a welded joint? Give
some typical examples.
B. What would cause you to reject a welder's test piece?. Answer: A.
A test which does not destroy the boiler component, such as
radiograph, hydrostatic, ultrasonic, dy-pentrant, and magnetic-
particle tests.
, B. Porosity, lack of penetration, slag inclusions, and cracks on the
surface of the weld, or any other such defects nor meeting code
requirements.
◉ The cooling water from an air ejector intercondenser and after the
condenser is discharged directly into the.... Answer: condensate and
feed system
◉ What is excess air?. Answer: It is the quantity of air over and
above the theoretical amount required to burn carbon to CO2.
◉ What is the principal of operation of an air ejector?. Answer: An
air ejector consists essentially of a steam nozzle discharging a high
velocity jet of steam across a suction chamber and through a
venturi-shaped compression tube. Air or gasses are entrained by jet
and discharged through the throat, where the velocity energy is
converted into pressure, thereby compressing the mixture to a lower
vacuum.
◉ The atmosphere is composed basically of two gases. What are
they and in what volume?. Answer: Oxygen=21%
Nitrogen=79%
COMPLETE QUESTIONS AND ANSWERS
◉ List 3 scale forming compounds found in feedwater and indicate if
it forms insoluble, scale, hard scale, or sludge and soft scale. Answer:
1. Calcium Sulphate- forms insoluble scale
2. Calcium Carbonate- forms sludge and soft scale
3. Calcium Silicate- forms hard scale
4. Magnesium carbonate- forms sludge and soft scale
5. Silica- forms hard scale
◉ Does a reheater on a boiler require a safety valve. Answer: Yes
The re-heater safety valve(s) must be capable of relieving all the
steam the re-heater can generate. At least 15% of the required
capacity shall be placed on the re-heater outlet.
◉ A flue gas analysis showed the following percentages by volume:
CO2= 15%, oxgen=5%. What is the excess air based on the
readings?. Answer: Excess Air= Oxygen by volume/ CO2 by volume =
5/15= 33.33%
,◉ What is the difference between active and inactive pitting?.
Answer: pustules/blisters having a brown oxide covering for over
the put, and then active are filled with black oxide of iron
◉ How are small turbine shafts aligned to a boiler feed pump shaft
and how do you check for shaft alignment?. Answer: The central
relation of the two shafts may be checked by placing a straight edge
parrell to the two shafts across the rims of the coupling flanges. This
check should be applied at four places about the flanges. The Parrell
relation of the two shafts can be checked measuring the distance
between the coupling flange faces with a feeler gauge. if there two
shafts are Parrell, these measurements will be equal at all points on
the coupling. also, a dial indicator can be used.
◉ Explain the results of using steam at a lower superheat
temperature than the turbine is designed for.. Answer: There will be
a loss of power and efficiency in the turbine because there will be
less total heat in the steam in the later stages.
There will also be an increase in corrosion and erosion in the blades
in the later stages due to this increased moisture content in the
steam.
◉ Mass general law Chapter 146 section 45A, when do refrigeration
and air conditioning systems need to be inspected?. Answer: 20 tons
or over if not used exclusively for agricultural, horticultural, or
,floricultural purposes or under the jurisdiction of the US
government.
◉ If the PH of boiler water is increased from 9 to 11, how many
times more basic is the water?. Answer: 100 times
◉ Considering pressure and temperature conditions, when shall a
boiler be built in accordance with the rules in the Power Boiler
Section I of the ASME Code?. Answer: When pressure exceeds 15 PSI
for a steam boiler or 160 psi and/or 250-degree F for a water boiler
◉ What is meant by reinforcement of a weld?. Answer: The amount
of weld above the surface of the plate on the face side. This ensures
full penetration for full thickness of plates to be joined.
◉ A. What is meant by a nondestructive test of a welded joint? Give
some typical examples.
B. What would cause you to reject a welder's test piece?. Answer: A.
A test which does not destroy the boiler component, such as
radiograph, hydrostatic, ultrasonic, dy-pentrant, and magnetic-
particle tests.
, B. Porosity, lack of penetration, slag inclusions, and cracks on the
surface of the weld, or any other such defects nor meeting code
requirements.
◉ The cooling water from an air ejector intercondenser and after the
condenser is discharged directly into the.... Answer: condensate and
feed system
◉ What is excess air?. Answer: It is the quantity of air over and
above the theoretical amount required to burn carbon to CO2.
◉ What is the principal of operation of an air ejector?. Answer: An
air ejector consists essentially of a steam nozzle discharging a high
velocity jet of steam across a suction chamber and through a
venturi-shaped compression tube. Air or gasses are entrained by jet
and discharged through the throat, where the velocity energy is
converted into pressure, thereby compressing the mixture to a lower
vacuum.
◉ The atmosphere is composed basically of two gases. What are
they and in what volume?. Answer: Oxygen=21%
Nitrogen=79%
