API 571 Study Guide

Practice Questions
This following is a study aid that you can use to learn the details and content of API RP-571, Damage
Mechanisms Affecting Fixed Equipment in the Refining Industry. There will be about 4-7 questions
from this document on your API exam. We do not spend time in class discussing this publication. So it is
important that you become familiar with this content in your personal study sessions.
The questions in this study aid are by damage mechanism. An answer key is given at the end of the study
guide. We suggest you read about the damage mechanism a couple of times before answer the questions.
We suggest that you do this study guide at least twice prior to the API exam.

Brittle Fracture (4.2.7)

1.

A brittle fracture:
a)
b)
c)
d)

2.

Which of the following materials is least affected by brittle fracture?

a)
b)
c)
d)
e)

3.

The materials fracture toughness

Maximum operating temperature
Stress concentration at a flaw
Magnitude of the residual stresses

Most brittle failures occur:

a)
b)
c)
d)

MSTS

Charpy impact test

Guided bend test
Metallography
Tension test
Physical fitness test

Which of the following is not a critical factor that contributes to a brittle fracture?
a)
b)
c)
d)

6.

1955.
1962.
1973.
1987.

What test is used to determine a materials toughness?

a)
b)
c)
d)
e)

5.

Carbon steel
Chromes
300 series stainless steel
400 series stainless steel
All stainless steels

ASME Section VIII had few limitations concerning brittle fracture prior to:
a)
b)
c)
d)

4.

is caused by stress cycles.

is always the result of thermal stresses.
grow very rapidly with minimum deformation prior to failure.
grows slowly and is dependent on time and stress.

below the impact transition temperature.

on thinner materials.
on clean steel.
while in operation at elevated temperatures.

December 2005

API 571 Study Guide

Practice Questions
7.

Most brittle failures appear as:

a)
b)
c)
d)

8.

branched cracking.
intergranular cracking.
ductile tears.
cleveage.

Which of the following is not a method used to prevent brittle fracture?

a)
b)
c)
e)

Thorough inspections
Strict controls on selecting construction materials
Post weld heat treatment
Controlling minimum operating temperatures

Erosion/Erosion Corrosion (4.2.14)

1.

The removal of surface material by impacting materials is called:

a)
b)
c)
d)

2.

The removal of a materials protective scale by impacting materials is called:

a)
b)
c)
d)

3.

Impact angle (angle that impacting particles strike metal)

Tensile strength of the metal
Velocity of impacting particles
Corrosiveness of the environment

A prime location for erosion is:

a)
b)
c)
d)

MSTS

Impact angle (angle that impacting particles strike metal)

Size of impacting particles
Velocity of impacting particles
Density of impacting particles
Corrosiveness of the environment

Which of the following is not a primary factor contributing to erosion-corrosion?

a)
b)
c)
d)

5.

erosion.
erosion-corrosion.
erosion or erosion-corrosion.
IPRSC (imparting particle removal of scale corrosion).

Which of the following is not a primary factor contributing to erosion?

a)
b)
c)
d)
e)

4.

erosion.
erosion corrosion.
erosion or erosion corrosion.
IPC (imparting particle corrosion).

in catalyst piping.
downstream of a gate valve.
any superheated steam piping.
upstream of a pump.

December 2005

API 571 Study Guide

Practice Questions
Thermal Fatigue (4.2.9)
1.

Thermal fatigue is caused by:

a)
b)
c)
d)

2.

Time to failure by thermal fatigue is primarily affected by:

a)
b)
c)
d)

3.

cyclic stresses that come from temperature variations.

long term operation at elevated temperatures.
excessive thermal growth.
hours of physical activity during a hot summer day.

magnitude of stress and operating temperature.

magnitude of stress and number of cycles.
carbon content in material and operating temperature.
carbon content in material and number of cycles.

Thermal fatigue becomes of concern if the temperature swings exceed:

a)
50 oF.
b) 100 oF.
c) 200 oF.
d) 400 oF.

4.

Which of the following is not a prime candidate for thermal fatigue?

a)
b)
c)
d)
e)

5.

Which of the following is not a primary initiating point for thermal fatigue?
a)
b)
c)
d)

6.

MSTS

initiate on the surface of the component.

initiate in the subsurface of the component.
grow very rapidly (at the speed of sound in the material).
are very tight and narrow.

Many thermal fatigue cracks are filled with:

a)
b)
c)
d)

8.

Notches
Rounded pits
Nozzle-to-shell welds
Weld toes

Thermal fatigue cracks usually:

a)
b)
c)
d)

7.

Coke drums
Steam actuated soot blowers
Mix points of hot and cold streams
600 psig steam piping
Welds joining materials having different coefficients of expansion

chlorides.
hydroslime.
oxides.
sulfides.

Ways to prevent thermal fatigue include reducing stress concentrators by making _______________
transitions at places where the wall thickness changes.

December 2005

API 571 Study Guide

Practice Questions
Atmosphere Corrosion (4.3.2)
1.

Atmospheric corrosion is of greatest concern in:

a)
b)
c)
d)

2.

Which of the following materials is least affected by atmospheric corrosion?

a)
b)
c)
d)

3.

Bird poop
Increasing annual rainfalls
Locations where moisture is trapped
Increasing operating pressures
Increasing amounts of airborne contaminates

have an aggressive inspection program.

reduce airborne particulates.
install and maintain appropriate coatings.
shoot all birds that cross the plant fence.
build new petrochemical facilities in a dry desert.

Atmospheric corrosion:
a)
b)
c)
d)

MSTS

________ mpy
________ mpy
________ mpy
________ mpy

The best way to prevent failures by atmospheric corrosion is to:

a)
b)
c)
d)
e)

6)

Dry rural environments

Inland locations with moderate humidity or rainfall
Industrial environments with airborne acids or sulfur compounds
Marine environments

Which of the following does not increases the likelihood of atmospheric corrosion?
a)
b)
c)
d)
e)

5.

Carbon steel
Chromes
Stainless steels
Copper alloyed with aluminum

List the approximate corrosion rates for the following conditions.

a)
b)
c)
d)

4.

dry climates in rural locations.

dry climates in industrial locations.
wet climates in rural locations.
wet climates in industrial locations.

can cause either uniform or localized wall loss.

always causes localized wall loss.
always causes uniform wall loss.
is best detected using profile RT.

December 2005

API 571 Study Guide

Practice Questions
Mechanical Fatigue (4.2.16)
1.

Which of the following materials are affected by mechanical fatigue cracking?

a)
b)
c)
d)

2.

Mechanical fatigue is caused by:

a)
b)
c)
d)

3.

Low Temps
Dirty Steel
Fine-grain
Notches
High ph

High Temps
Clean Steel
Coarse-grain
Smooth surface
Low ph

Not a factor
Not a factor
Not a factor
Not a factor
Not a factor

Non-normalized carbon steel

Normalized carbon steel
Stainless steel
Titanium

The endurance limit is usually about:

a)
b)
c)
d)
e)

MSTS

Temperature:
Steel Properties:
Grain structure:
Surface Condition:
Process ph:

Which material does not have an endurance limit?

a)
b)
c)
d)

6.

transition limit.
endurance limit.
hardening limit.
speed limit.

Circle which condition contributes to mechanical fatigue

a)
b)
c)
d)
e)

5.

cyclic stresses occurring over a long period of time.

higher than average stresses at high temperatures.
constant stresses occurring at low temperatures.
cyclic operating conditions of bird poop then rain, bird poop then rain, etc.

Fatigue will not occur in carbon steel if stresses are below the:
a)
b)
c)
d)

4.

Only carbon steel

Only carbon steel and chromes
Only carbon steel, and high nickel alloys
All materials

10-20% of a materials ultimate tensile strength.

40-50% of a materials ultimate tensile strength
10-20% of a materials yield strength.
40-50% of a materials yield strength.
half way up the ladder of a 150 column (tower).

December 2005

API 571 Study Guide

Practice Questions
7.

Inspecting for high-cycle fatigue can be difficult since:

a)
b)
c)
d)

8.

the cracks are extremely tight.

predicting the location of cracking is difficult.
once the crack begins, only a few cycles are needed for the crack to lead to failure.
often the equipment is vibrating making non-destructive evaluations difficult.

Mechanical fatigue can cause cracks that initiate from the surface and often form a:
a)
b)
c)
d)
e)

clam shell appearance.

snail shell appearance.
turtle shell appearance.
Shell Oil shell appearance.
taco shell appearance.

Sulfidation (4.4.2)
1.

Which of the following is not a major factor associated with corrosion by sulfidation?
a)
b)
c)
d)

2.

Sulfidation of iron-based alloys usually begins at about:

a)
b)
c)
d)

3.

impacting particles.
sulfur compounds decomposing at higher temperatures.
sulfur compounds being created in the FCCU (Cat Cracking Unit).
elemental sulfur collecting in stagnate areas, e.g. dead legs.
operators failing to adequately control the ph of sulfur streams.

Sulfidation usually creates:

a)
b)
c)
d)
e)
f)

MSTS

chromium content in the material increases.

nickel content in the material increases.
materials tensile strength decreases.
materials tensile strength increases.

Sulfidation is primarily caused by:

a)
b)
c)
d)
e)

5.

150 oF.
250 oF.
500 oF.
1100 oF.

Resistance to sulfidation increases as the:

a)
b)
c)
d)

4.

Alloy composition
Operating pressure
Operating temperature
Sulfur content

uniform corrosion.
isolated pitting.
intergranular cracking.
transgranular cracking.
hard and brittle zones.
inspection nightmares.

December 2005

API 571 Study Guide

Practice Questions
Boiler Water Condensate Corrosion (4.3.5)
1.

Which of the following is not a major factor associated with boiler water condensate corrosion?
a)
b)
c)
d)
e)

2.

Corrosion from oxygen in boiler feed water usually creates:

a)
b)
c)
d)
e)

3.

Oxide scavengers are added to process

Oxygen scavengers are added to process
Sulfide scavengers are added to process
Sulfur scavengers are added to process

What method is most used to assure boiler feed water corrosion is not occurring?
a)
b)
c)
d)

MSTS

injecting chlorines to kill microbiological bugs.

injecting caustic to lower the ph to < 4.0.
lowering solids content in boiler feed water to less than 50 ppm.
maintaining a protective corrosion layer of magnetite (Fe3O4).

What treatment is used to prevent boiler feed water corrosion?

a)
b)
c)
d)

5.

uniform corrosion.
isolated pitting.
intergranular cracking.
transgranular cracking.
hard and brittle zones.

Protection in a boiler from boiler feed water corrosion is accomplished by:

a)
b)
c)
d)

4.

Operating pressure
Oxygen content
Carbon dioxide content
Process ph
Temperature

Spot UT readings at turbulent areas

Profile RT at turbulent areas
Profile RT at stagnant areas
Laboratory analysis of boiler feedwater

December 2005

API 571 Study Guide

Practice Questions
Answer Key
Brittle Fracture (4.2.7)
1.
2.
3.
4.
5.
6.
7.
8.

Mechanical Fatigue (4.2.16)

c
c
d
a
b
a
d
a

1.
2.
3.
4a.
4b.
4c.
4d.
4e.
5.
6.
7.
8.

Erosion/Erosion-Corrosion (4.2.14)
1.
2.
3.
4.
5.

a
b
e
b
a

Sulfidation (4.4.2)
1.
2.
3.
4.
5.

Thermal Fatigue (4.2.9)

1.
2.
3.
4.
5.
6.
7.
8.

d
a
b
Not a factor
Dirty steel
Coarse grain
Notches
Not a factor
c
b
c
a

a
b
c
d
b
a
c
smooth

b
c
a
b
a

Boiler Water Condensate (4.3.5)

1.
2.
3.
4.
5.

a
b
d
b
d

Atmospheric Corrosion (4.3.2)

1.
2.
3a.
3b.
3c.
3d.
4.
5.
6.

MSTS

d
c
< 1 mpy
1-3 mpy
5-10 mpy
20 mpy
d
c
a

December 2005