BOILERMAKER REAL 2025”2026 EXAM REVIEW 150 QUESTIONS AND
CORRECT ANSWERS WITH RATIONALES COVERING THE MOST TESTED
QUESTIONS GUARANTEE OVER 80% PASSMARK
1. What is the primary purpose of a boiler in an industrial setting?
A. Produce electricity directly
B. Generate steam for power, heating, or process use ☑
C. Store liquids
D. Filter gases
Rationale: Boilers convert water into steam for heating, power generation, or industrial
processes; they do not directly generate electricity.
2. Which welding process is most commonly used for thick steel plates in boiler construction?
A. MIG
B. SMAW (Stick Welding) ☑
C. TIG
D. Laser welding
Rationale: Shielded Metal Arc Welding (SMAW) is robust and versatile, making it ideal for heavy
steel construction in boiler work.
3. What does the term “butt weld” mean?
A. Welding at a right angle
B. Joining two pieces of metal end-to-end in the same plane ☑
C. Overlapping weld
D. Corner weld
Rationale: A butt weld connects two metal pieces in a straight line, commonly used in boiler
seams for strength and continuity.
4. Which tool is used to check the straightness of a metal edge?
A. Hammer
B. Level
C. Straightedge ☑
D. Chisel
Rationale: A straightedge provides a reference line to detect bends or warps in metal edges.
,5. Why is preheating steel important before welding thick plates?
A. Reduces paint adhesion
B. Prevents cracking by reducing thermal stress ☑
C. Saves welding time
D. Increases corrosion
Rationale: Preheating slows cooling, reducing residual stress and the risk of cracks in thick steel
welds.
6. Which safety equipment is essential when performing arc welding?
A. Safety shoes only
B. Gloves only
C. Helmet, gloves, apron, and safety glasses ☑
D. Hearing protection only
Rationale: Arc welding emits UV radiation, sparks, and heat; full protective gear prevents burns,
eye injuries, and electric shock.
7. What does the term “NDT” stand for in boiler inspection?
A. New Design Testing
B. Non-Destructive Testing ☑
C. Normal Development Technique
D. National Draft Test
Rationale: NDT methods (ultrasonic, radiography, dye penetrant) evaluate weld integrity
without damaging components.
8. Which NDT method is best for detecting surface cracks?
A. Ultrasonic testing
B. Radiography
C. Dye penetrant testing ☑
D. Magnetic particle testing
Rationale: Dye penetrant highlights surface defects by capillary action, making cracks visible
under inspection.
,9. What is the function of a boiler’s safety valve?
A. Heat water
B. Increase pressure
C. Release excess pressure to prevent explosion ☑
D. Monitor water level
Rationale: Safety valves prevent pressure from exceeding design limits, protecting the boiler
and personnel.
10. When reading a boiler blueprint, what does a dashed line typically indicate?
A. Welding seam
B. Hidden or internal features ☑
C. Pipe diameter
D. Electrical conduit
Rationale: Dashed lines represent parts not visible in the current view, such as internal
components or hidden edges.
11. Which metal is commonly used for high-pressure boiler tubes?
A. Aluminum
B. Copper
C. Carbon steel or alloy steel ☑
D. Brass
Rationale: Carbon steel and alloy steel withstand high temperatures and pressures typical in
boiler applications.
12. What is the main hazard when cutting steel with an oxy-acetylene torch?
A. Noise
B. Fire and burns ☑
C. Radiation
D. Electric shock
Rationale: Oxy-fuel cutting produces sparks, molten metal, and intense heat, requiring fire
precautions and PPE.
13. What is the purpose of a backstep welding technique?
A. Decorative effect
, B. Reduce distortion in long welds ☑
C. Increase welding speed
D. Strengthen corners only
Rationale: Backstepping distributes heat more evenly, minimizing warping in long weld seams.
14. Which type of joint is used when two plates meet at a right angle?
A. Butt joint
B. Corner joint ☑
C. Lap joint
D. Edge joint
Rationale: Corner joints connect plates at a 90-degree angle, common in boiler casings and
supports.
15. Why is proper venting important when working inside a boiler?
A. Prevent paint fumes
B. Avoid accumulation of toxic gases or oxygen deficiency ☑
C. Reduce welding fumes
D. Prevent water spillage
Rationale: Proper ventilation prevents asphyxiation or poisoning when confined spaces contain
residual gases.
16. Which type of flame is preferred for welding carbon steel with an oxy-acetylene torch?
A. Carburizing
B. Neutral flame ☑
C. Oxidizing
D. Blue flame only
Rationale: A neutral flame avoids adding or removing carbon, ensuring proper metallurgical
properties in the weld.
17. What is the typical angle for a bevel in a butt joint for thick plate welding?
A. 15°
B. 30°
C. 30°–45° ☑
D. 60°–75°
CORRECT ANSWERS WITH RATIONALES COVERING THE MOST TESTED
QUESTIONS GUARANTEE OVER 80% PASSMARK
1. What is the primary purpose of a boiler in an industrial setting?
A. Produce electricity directly
B. Generate steam for power, heating, or process use ☑
C. Store liquids
D. Filter gases
Rationale: Boilers convert water into steam for heating, power generation, or industrial
processes; they do not directly generate electricity.
2. Which welding process is most commonly used for thick steel plates in boiler construction?
A. MIG
B. SMAW (Stick Welding) ☑
C. TIG
D. Laser welding
Rationale: Shielded Metal Arc Welding (SMAW) is robust and versatile, making it ideal for heavy
steel construction in boiler work.
3. What does the term “butt weld” mean?
A. Welding at a right angle
B. Joining two pieces of metal end-to-end in the same plane ☑
C. Overlapping weld
D. Corner weld
Rationale: A butt weld connects two metal pieces in a straight line, commonly used in boiler
seams for strength and continuity.
4. Which tool is used to check the straightness of a metal edge?
A. Hammer
B. Level
C. Straightedge ☑
D. Chisel
Rationale: A straightedge provides a reference line to detect bends or warps in metal edges.
,5. Why is preheating steel important before welding thick plates?
A. Reduces paint adhesion
B. Prevents cracking by reducing thermal stress ☑
C. Saves welding time
D. Increases corrosion
Rationale: Preheating slows cooling, reducing residual stress and the risk of cracks in thick steel
welds.
6. Which safety equipment is essential when performing arc welding?
A. Safety shoes only
B. Gloves only
C. Helmet, gloves, apron, and safety glasses ☑
D. Hearing protection only
Rationale: Arc welding emits UV radiation, sparks, and heat; full protective gear prevents burns,
eye injuries, and electric shock.
7. What does the term “NDT” stand for in boiler inspection?
A. New Design Testing
B. Non-Destructive Testing ☑
C. Normal Development Technique
D. National Draft Test
Rationale: NDT methods (ultrasonic, radiography, dye penetrant) evaluate weld integrity
without damaging components.
8. Which NDT method is best for detecting surface cracks?
A. Ultrasonic testing
B. Radiography
C. Dye penetrant testing ☑
D. Magnetic particle testing
Rationale: Dye penetrant highlights surface defects by capillary action, making cracks visible
under inspection.
,9. What is the function of a boiler’s safety valve?
A. Heat water
B. Increase pressure
C. Release excess pressure to prevent explosion ☑
D. Monitor water level
Rationale: Safety valves prevent pressure from exceeding design limits, protecting the boiler
and personnel.
10. When reading a boiler blueprint, what does a dashed line typically indicate?
A. Welding seam
B. Hidden or internal features ☑
C. Pipe diameter
D. Electrical conduit
Rationale: Dashed lines represent parts not visible in the current view, such as internal
components or hidden edges.
11. Which metal is commonly used for high-pressure boiler tubes?
A. Aluminum
B. Copper
C. Carbon steel or alloy steel ☑
D. Brass
Rationale: Carbon steel and alloy steel withstand high temperatures and pressures typical in
boiler applications.
12. What is the main hazard when cutting steel with an oxy-acetylene torch?
A. Noise
B. Fire and burns ☑
C. Radiation
D. Electric shock
Rationale: Oxy-fuel cutting produces sparks, molten metal, and intense heat, requiring fire
precautions and PPE.
13. What is the purpose of a backstep welding technique?
A. Decorative effect
, B. Reduce distortion in long welds ☑
C. Increase welding speed
D. Strengthen corners only
Rationale: Backstepping distributes heat more evenly, minimizing warping in long weld seams.
14. Which type of joint is used when two plates meet at a right angle?
A. Butt joint
B. Corner joint ☑
C. Lap joint
D. Edge joint
Rationale: Corner joints connect plates at a 90-degree angle, common in boiler casings and
supports.
15. Why is proper venting important when working inside a boiler?
A. Prevent paint fumes
B. Avoid accumulation of toxic gases or oxygen deficiency ☑
C. Reduce welding fumes
D. Prevent water spillage
Rationale: Proper ventilation prevents asphyxiation or poisoning when confined spaces contain
residual gases.
16. Which type of flame is preferred for welding carbon steel with an oxy-acetylene torch?
A. Carburizing
B. Neutral flame ☑
C. Oxidizing
D. Blue flame only
Rationale: A neutral flame avoids adding or removing carbon, ensuring proper metallurgical
properties in the weld.
17. What is the typical angle for a bevel in a butt joint for thick plate welding?
A. 15°
B. 30°
C. 30°–45° ☑
D. 60°–75°
