These are the high-frequency topics (based on exam breakdown + practice banks):

 

1. Source Inspection Basics

• Roles & responsibilities of inspector
• Authority (e.g. SIMP vs ITP vs PO)
• Ethics & communication

📌 Example:

“Which document defines inspector authority?”
✔ Answer: SIMP (Source Inspection Management Program)

 

 

2. Inspection Planning & Documentation

• Inspection & Test Plan (ITP)
• Purchase Order (PO) checks
• Vendor documentation review

📌 Repeated concept:

• What must be verified in PO?
• When to witness vs hold point?

 

3. Criticality & Risk-Based Inspection

• Why perform criticality assessment
• Risk vs consequence

📌 Example:

Purpose of criticality assessment?
✔ Identify equipment requiring inspection based on risk

 

 

4. Manufacturing & Fabrication

• Casting, forging, welding basics
• Heat treatment
• Material identification

👉 Questions are basic-level, not deep engineering

 

 

5. NDT (Very Common)

• RT, UT, MT, PT basics
• When to use each method
• Acceptance criteria (basic)

📌 Typical repeats:

• Which NDT detects surface cracks?
• When is UT preferred?

 

 

6. Rotating Equipment (Core Area)

• Pumps (centrifugal, reciprocating)
• Compressors
• Turbines
• Gears

📌 Frequent question styles:

• Components identification
• Failure causes
• Inspection points

 

 

7. Inspection Tools & Methods

• Measuring tools (calipers, micrometers)
• Alignment checks
• Visual inspection

 

 

8. Final Inspection & Testing

• Hydrotest vs performance test
• Documentation review before release
• Punch list handling

🔥 WHY THESE QUESTIONS ARE TRICKY

They test mindset, not knowledge:

👉 Wrong thinking:

• “Looks okay → accept”
• “Small issue → ignore”
• “I think it’s fine → decide”

 

• Follow process
• Escalate uncertainty
• Never assume authority
• Document everything

 

 

🧠 GOLDEN RULE (MEMORIZE THIS)

When stuck, choose the answer that:

✔ Follows procedure
✔ Involves documentation
✔ Escalates decisions
✔ Protects safety
✔ Avoids assumptions

 

 

SECTION 1: Inspector Authority & Decisions (Most Failed Area)

1. Vendor completes work before inspector arrival at hold point. What is the BEST action?

   A. Accept work
   B. Reject work
   C. Escalate and review records
   D. Ignore

👉 Answer: C
➡️ You don’t auto-reject—you escalate and verify

 

 

2. Inspector believes deviation is minor and acceptable. What should be done?

   A. Approve it
   B. Accept verbally
   C. Report to purchaser
   D. Ignore

👉 Answer: C
➡️ Inspector NEVER approves deviations

 

 

3. Vendor insists inspection is unnecessary. Inspector should:

   A. Agree
   B. Skip inspection
   C. Follow ITP and escalate if needed
   D. Leave

👉 Answer: C

 

 

4. Inspector disagrees with vendor interpretation of spec.

   A. Accept vendor view
   B. Enforce own decision
   C. Escalate for clarification
   D. Ignore

👉 Answer: C

 

 

5. Inspector is asked to sign incomplete report.

   A. Sign
   B. Refuse and escalate
   C. Ignore
   D. Delay

👉 Answer: B

 

 

🔴 SECTION 2: Documentation & ITP Confusion

6. ITP is unclear about inspection stage. What should inspector do?

   A. Guess
   B. Follow vendor
   C. Escalate for clarification
   D. Skip

👉 Answer: C

 

 

7. PO and drawing conflict. Which governs?

   A. PO
   B. Drawing
   C. ITP
   D. Escalate

👉 Answer: D
➡️ Don’t assume hierarchy in conflict

 

 

8. Latest revision of drawing not available.

   A. Use old revision
   B. Continue
   C. Stop and report
   D. Ask technician

👉 Answer: C

 

 

9. Vendor uses unapproved procedure.

   A. Accept
   B. Reject
   C. Escalate
   D. Ignore

👉 Answer: C

 

 

10. Missing test report during final inspection.
    A. Accept equipment
    B. Reject
    C. Hold until document provided
    D. Ignore

👉 Answer: C

 

 

🔴 SECTION 3: NDT Application Confusion

11. Which method is BEST for detecting internal weld defects?

    A. PT
    B. MT
    C. UT
    D. Visual

👉 Answer: C

 

 

12. MT cannot be used on:

    A. Steel
    B. Aluminum
    C. Iron
    D. Carbon steel

👉 Answer: B

 

 

13. PT requires surface to be:

    A. Rough
    B. Clean
    C. Painted
    D. Wet

👉 Answer: B

 

 

14. UT requires which for proper transmission?

    A. Air
    B. Couplant
    C. Oil only
    D. Heat

👉 Answer: B

 

 

15. RT is hazardous because of:

    A. Heat
    B. Sound
    C. Radiation
    D. Pressure

👉 Answer: C

 

 

🔴 SECTION 4: Rotating Equipment Weak Concepts

16. Excessive vibration is MOST likely caused by:

    A. Painting
    B. Misalignment
    C. Cooling
    D. Color

👉 Answer: B

 

 

17. Cavitation occurs due to:

    A. High pressure
    B. Low pressure at suction
    C. High temperature
    D. Speed

👉 Answer: B

 

 

18. Bearing failure commonly due to:

    A. Lubrication issues
    B. Alignment
    C. Contamination
    D. All

👉 Answer: D

 

 

19. Mechanical seal failure leads to:

    A. Noise
    B. Leakage
    C. Speed
    D. Pressure

👉 Answer: B

 

 

20. Coupling misalignment causes:

    A. Smooth operation
    B. Vibration
    C. Cooling
    D. Silence

👉 Answer: B

 

 

 

🔴 SECTION 5: Real Inspection Scenarios (MOST IMPORTANT)

21. Inspector finds defect but vendor says “acceptable”.

    A. Accept
    B. Reject
    C. Verify against spec and escalate
    D. Ignore

👉 Answer: C

 

 

22. Equipment passes test but wrong procedure used.

    A. Accept
    B. Reject
    C. Escalate
    D. Ignore

👉 Answer: C

 

 

23. Calibration certificate expired.

    A. Use tool
    B. Ignore
    C. Stop and report
    D. Adjust

👉 Answer: C

 

 

24. Inspector cannot attend witness point.

    A. Reject work
    B. Accept
    C. Review records later
    D. Ignore

👉 Answer: C

 

 

25. Vendor rushing inspection process.

    A. Speed up
    B. Ignore
    C. Follow procedure strictly
    D. Skip steps

👉 Answer: C

 

 

🧠 HOW TO USE THESE DRILLS

If you got any wrong, focus on this pattern:

 

🔥 Weak mindset indicators:

• You chose “accept” too quickly
• You chose “reject” without escalation
• You trusted vendor too much

 

 

✅ CORRECT SIRE MINDSET (MEMORIZE)

When unsure, ALWAYS lean toward:

• 📄 Check documents
• 📢 Escalate
• 🧾 Document
• ⚠️ Protect safety
• ❌ Do NOT decide beyond authority
• 📢 Focus on inspector’s role