API 571 Introduction to Damage Mechanisms

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API 571 Introduction

66* Damage Mechanisms Affecting
Fixed Equipment in the Refining Industry
 In 2013, the API 571 2nd Edition comes into effect using 66 Damage Mechanisms
Saudi Aramco: Company General Use

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Welcome to API 571 Course & Self Study

1. The API 571 exam is very comprehensive, with 75 difficult questions covering many of the 66
mechanisms and the following categories. A summary of API 571 Exam Questions (Sept 2010)
showed the following “EXAMINER QUESTION SELECTION TENDENCIES” as follows:
 Critical Factors  29 questions of 70 utilized this section (answer)  # 1 priority

 Description of Damage  17 questions of 70 utilized this section (answer)  # 2 priority
 Insp. & Monitoring  12 questions of 70 utilized this section (answer)  # 3 priority
 Prevention/Mitigation  11 questions of 70 utilized this section (answer)  # 4 priority
 Affected Units/Equip  10 questions of 70 utilized this section (answer)  # 5 priority
 Affected Materials  4 questions of 70 utilized this section (answer)  (Low priority)
 Appearance or Morph 4 questions of 70 utilized this section (answer)  (Low priority)
 Related Mechanisms  3 questions of 70 utilized this section (answer)  (Low priority)
2. If you do not study the above details well in the areas outlined as instructed, you will likely
not do very well on the exam. It is expected that you can pass the exam (49 of 70 = 70%) if you:
 Read API 571 (using the module) at least three times & follow training module tips
 Take practice exam “honestly” and score above 70%+ (Exam available Feb 2011)
3. We recommend that you use “Flip the switch” techniques for Self-Study* (*E-Library
Folder # 27, Subfolder # 1 – Sample Study & Testing Affirmation) See Ed Langla for assistance
here & spend a minimum of 100-125 hrs of Self-Study on API 571 & related Study Questions.
4. API 510/570/653 Exams cover 23 damage mechanisms! Give them great attention!
Par. 4.2.3 – Temper Embrittlement .………………………………..…  API 510 only
Par. 4.2.7 – Brittle Fracture …….………………………………..…….  API 510/570/653
Par. 4.2.9 – Thermal Fatigue ……..…………………………….………  API 510/570 only
Par. 4.2.14 – Erosion/Erosion Corrosion ……..…………………….…  API 510/570 only
Par. 4.2.16 – Mechanical Fatigue ………...…………………………….  API 510/570/653
Par. 4.2.17 – Vibration-Induced Fatigue ………..………………….…  API 570 only
Par. 4.3.1 – Galvanic Corrosion …………..…………………………… API 570 only
Par. 4.3.2 – Atmospheric Corrosion ……………………………..…….  API 510/570/653
Par. 4.3.3 – Corrosion under Insulation (CUI) ………………….…….  API 510/570/653
Par. 4.3.4 – Cooling Water Corrosion ………………….………………  API 510 only
Par. 4.3.5 – Boiler Water Condensate Corrosion .……………………  API 510/570 only
Par. 4.3.7 – Flue Gas Dew Point Corrosion……..………………….…  API 570 only
Par. 4.3.8 – Microbiologically Induced Corrosion (MIC) …………… API 570/653 only
Par. 4.3.9 – Soil Corrosion …………………………………………….. API 570/653 only
Par. 4.3.10 – Caustic Corrosion ……………………………………….. API 510/653 only
Par. 4.4.2 – Sulfidation ………………………………………………… API 510/570 only
Par. 4.5.1 – Chloride Stress Corrosion Cracking (ClSCC)………….  API 510/570/653
Par. 4.5.2 – Corrosion Fatigue ………………….…………………….. API 510 only
Par. 4.5.3 – Caustic Stress Corr. Cracking (Caustic Embrittlement).  API 510/570/653
Par. 5.1.1.11 – Sulfuric Acid Corrosion………….…………………….. API 653 only
Par. 5.1.2.3 – Wet H²S Damage (Blistering/HIC/SOHIC/SCC)……… API 510 only
Par. 5.1.3.1 – High Temperature Hydrogen Attack (HTTA) ………..  API 510/570 only
5. No questions came from API 571 Sections 1.1, 3.1, 4.1, and 5.2. However, you should
understand these sections & know abbreviations/definitions! Good Luck in self-study!
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WHEN YOU STUDY …

REMEMBER THIS …
DESCRIPTION OF DAMAGE IS THE KEY
THIS GIVES YOU “TIPS” TO SEARCH
FOR THOSE “REPEATED” ITEMS …
Example See DM #1 (Sulfidation):
4.4.2.1 Description of Damage
Corrosion of CS and other alloys resulting from their reaction with sulfur compounds in high temp
environments. The presence of hydrogen accelerates corrosion. It is also called sulfidic corrosion.
This “short and sweet” Description of Damage leads us to several great “likely” questions:
 Critical factors (3) = Alloy composition/temp/concentration of corrosive compounds
 Critical factors (temp) = 500°F (260°C) Rule = Temperature where Sulfidation begins
 Critical factors regarding Alloys  McConomy Curve & increase the Cr % rates
 Presence of Hydrogen = accelerates Sulfidic corrosion
 The alias = other name for Sulfidation = Sulfidic Corrosion
Additional important points!!!

 REPEATED ITEMS not in Description of Damage are often on exams
What about “Sulfide scales” formed? How many sections cover Sulfide scale
Answer: Sulfide scale is covered twice in critical factors, and in appearance
and also in Prevention … Wouldn’t this make a great exam question???
Q: Susceptibility of an alloy to sulfidation is determined by its ability to:
Answer (of course): Form protective sulfide scales
 “UNIQUE” or “UNUSUAL” ITEMS are often found on API exams
o Proactive & Retroactive PMI Programs
o Other things that make a DM unique
 The close connection with similar DMs … such as Hi-Temp H2 / H2S
Corrosion (Section 5.1.1.5)
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API 571 COURSE & SELF STUDY GUIDE

Instructions: Study Using the Hi-Lite copy of API 571 … Cover answers and test yourself
DM # 1 of 66 … SULFIDATION  12 questions
1a. Sulfidation damage is accelerated by the presence of:
A) Hydrogen B) Sulfur C) Salts D) Corrosive Water
Answer = A … See Paragraph 4.4.2.1 (Description of Damage)
1b. Which material is highly resistant to Sulfidation damage in most refining process
environments?
A) Carbon steels B) Low alloy steels ≥ 7% Chrome

C) 400 Series SS D) 300 Series SS (304, 316, 321, 347)
Answer = D … Ref: 4.4.2.2.a & 4.4.2.3.d … Affected Materials & Critical Factors
1c. Sulfidation of iron-based alloys usually begins at metal temperatures above:
A) 500°F (260°C) B) 700°F (370°C) C) 900°F (482°C) D) 1000°F (538°C)
Answer = A … See Paragraph 4.4.2.3.c (Critical Factors)
1d. Increasing chromium content in Low alloys improves Sulfidation resistance. However,
there is little improvement until chromium content is increased to (what % Cr):
A) 3-5% B) 5-7% C) 7-9% D) 12%
Answer = C … Ref: 4.4.2.3.c & Fig. 4-65 McConomy Curves & 4.4.2.6.a … CF & P/M Par.
5.1.1.5.3.f & Fig 5.4  7 – 9% is the given rule in High Temp H²/H²S Corrosion
McConomy curves must be understood as well as the need to increase Cr% & use IOWs
1e. Which Curves are utilized to determine Sulfidation corrosion rates?
A) Couper-Gorman B) McConomy C) Nelson D) None of these
Answer = B … Ref: 4.4.2.3.c & Fig. 4-65 McConomy Curves & 4.4.2.6.a …
1f. Sulfidation occurs at high temps and is primarily caused by:
A) Sulfates & other reactions from decomposition of sulfur compounds at high temps
B) SO² & other reactions from decomposition of sulfur compounds at high temps
C) SO³ & other reactions from decomposition of sulfur compounds at high temps
D) H²S & other reactions from decomposition of sulfur compounds at high temps
Answer: D … Ref: 4.4.2.3.f … Critical Factors

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DM # 1 … SULFIDATION (12 Q&A)

1g. When Sulfidation damage is found, it most often (usually) appears as:
A) Localized corrosion B) High velocity erosion-corrosion
C) Uniform thinning D) Under-deposit (scale) corrosion
Answer = C … See Paragraph 4.4.2.5.a below (Appearance)

1h. Services susceptible to sulfidation will usually have component surfaces that are:
A) Covered with localized pitting B) Covered with sulfide scale
C) Uniformly corroded (general deep pits) D) Covered with under-deposit pitting
Answer = B … See Paragraph 4.4.2.5.b below (Appearance)

1i. Resistance to Sulfidation is generally achieved by:
A) Upgrading to a higher chromium alloy B) Upgrading to a SS or nickel steel
C) Utilization of effective hi-temp coatings D) None of these
Answer = A … See Paragraph 4.4.2.6 below (Prevention)

1j. Sulfidation occurs in piping and equipment:
A) In hi-temp environments where sulfur-containing streams are processed
B) In hi-temp environments where H2S exists regardless of percentage
C) In hi-temp environments where hydrocarbon steams are mixed
D) None of these are correct
Answer = A … See Paragraph 4.4.2.4.a (Affected Units or Equipment)
1k. In services where sulfidation is anticipated, what is used to check for alloy mix-ups that
can result in accelerated corrosion rates?
A) Proactive and retroactive PMI programs for alloy verification per API 578
B) Retroactive PMI programs for alloy verification per API 578
C) Proactive PMI programs for alloy verification per API 578
D) Alloy verification checks (chemical analysis) per API 578
Answer = A … 571, Para. 4.4.2.7.d & Reference 7 … DM # 1 … Insp & Monitoring
1k. Evidence of thinning from sulfidation is best detected using:
A) Shear wave UT due to preferential weld attack and weld metal loss
B) Alloy verification checks (chemical analysis) per API 578
C) UT thickness measurements and Profile Radiography
D) A combination of UT thickness and UT shearwave
Answer = C … 571, Para. 4.4.2.7.c … DM # 1 … Inspection & Monitoring
End of DM # 1  How did you do on 12 questions?

Did you peak at answers? Retest until you score above 90%
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DM # 2 … WET H²S DAMAGE 20 Q&A

2a. Regarding wet H2S damage, hydrogen blisters may form as (select most correct Ans):
A) Surface bulges on ID of a pipe or pressure vessel only if in contact with wet H2S environment
B) Surface bulges on both the OD, the ID of a pipe or vessel, and usually more severe on ID side
C) Surface bulges on the OD or ID and within the wall thickness of a pipe or pressure vessel
D) In any identified high stress areas anywhere in piping or vessels
Answer = C … Ref: 5.1.2.3.1.a … Description of Damage (Wet H2S Damage  Blistering)
2b. Regarding wet H2S damage, hydrogen blisters result from: (select most correct Ans):
A) Hydrogen that is generated by hydrogen gas coming from the process stream and corrosion
B) Hydrogen that is generated by hydrogen gas coming from the process stream only
C) Hydrogen that is generated by corrosion
D) None of these is correct
Ans = C … Ref: 5.1.2.3.1.a & Fig 5-34/35 … Description of Damage (Wet H2S  Blistering)
2c. Regarding wet H2S damage, which statement below regarding HIC is FALSE?
A) HIC occurs in some cases when neighboring or adjacent blisters link together to form cracks
B) Interconnecting cracks between blisters often have a stair step appearance
C) HIC is sometimes called stepwise cracking
D) None of these
Ans = D … Ref: 5.1.2.3.1.b & Fig 5-36/37/38 … Description of Damage (Wet H2S  HIC)
Note: A, B & C are true  Therefore D = False statement
2d. Regarding wet H2S damage, SOHIC appears as:
A) Cracking when neighboring or adjacent blisters link together (within the wall)
B) Interconnecting cracks between blisters having a stair step appearance (near HAZ)
C) Arrays of cracks stacked on top of each other in the base metal adjacent to the weld HAZ
D) None of these
Ans = C … Ref: 5.1.2.3.1.c & Fig 5-39/40 … Description of Damage (Wet H2S  SOHIC)
2e. Regarding wet H2S damage, which statement regarding SSC is FALSE?
A) SSC = cracking from absorption of atomic hydrogen produced by sulfide corrosion process
B) SSC = cracking that can initiate in localized zones of high hardness in weld metal and HAZ
C) SSC = cracking under combined action of tensile stress & corrosion if H2S alone is present
D) SSC = a form of hydrogen stress cracking that occurs on the metal surface
Answer = C … Ref: 5.1.2.3.1.d & Fig 5-42/43 … Description of Damage (Wet H2S  SSC)
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2f. Regarding wet H2S damage, which type of steels are particularly susceptible to SSC?
A) High silicone content carbon steels B) Low silicone content carbon steels
C) High strength carbon steels D) None of these are correct
Answer = C … Ref: 5.1.2.3.1.d & Fig 5-42/43 … Description of Damage (Wet H2S  SSC)
2g. Wet H2S damage affects:
A) Carbon steels only

B) Carbon steels and low alloy steels
C) Carbon steels, low alloy steels and 400 series SS
D) Carbon steels, low alloy steels, 400 series SS and some Nickel steels
Answer = B … Ref: 5.1.2.3.1.d & Fig 5-42/43 … Affected Materials (Wet H2S Damage)
2h. Regarding wet H2S damage, which of these below is NOT a critical factor?
A) Environmental conditions (pH, H2S level, contaminants, temperature)

B) Material properties (hardness, microstructure, strength)
C) Tensile stress levels (applied or residual)
D) Time of exposure
Answer = D … Ref: 5.1.2.3.3.a … Critical Factors (Wet H2S Damage)
2i. Regarding Wet H2S Damage, hydrogen permeation or diffusion rates are:
A) Minimal at pH 10 and increases at higher and decreases at lower pH values

B) Minimal at pH 7 and increases at both higher and lower pH values
C) Maximum at pH 10 and decreases at lower pH values
D) Minimal at pH 4 and increases at lower pH values
Answer: B … Ref: 5.1.2.3.3.b.i … Critical Factors (Wet H2S Damage  pH)
2j. Regarding Wet H2S Damage, which statement is FALSE regarding temperature?
A) Hydrogen charging potential increases with increasing temperature if the aqueous phase is not
eliminated by the elevated temperature
B) Blistering, HIC & SOHIC damage occur between ambient & 300°F (150°C) but can occur at
even higher temperatures
C) SSC cracking potential is maximized at near-ambient temps and generally occurs below about
180°F (82°C)
D) None of these are correct (All are true)
Answer: D … Ref: 5.1.2.3.3.b.3 … Critical Factors (Wet H2S Damage  Temperature)

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2k. Regarding Wet H2S Damage, which statement is FALSE regarding hardness?
A) CS used in refinery is susceptible to SSC if localized hardness zones above 237 HB exist
B) CS used in refinery should be controlled to produce weld hardness less than 200 HB
C) CS used in refinery should use NACE RP0472 guidelines to control SSC
D) None of these are correct (All are true)
Answer: D … Ref: 5.1.2.3.3.b.4 … Critical Factors (Wet H2S Damage  Hardness)
2L. Regarding Wet H2S Damage, which statement is FALSE regarding steelmaking?
A) An absence of visual blistering does not indicate H2S damage is inactive because subsurface
SOHIC damage may be present
B) Improving steel processing & cleanliness to minimize blisters & HIC damage can still leave
steel susceptible to SOHIC
C) SSC is often found in steels with high levels of inclusions and internal discontinuities
D) Inclusions and laminations provide sites for diffusing hydrogen to accumulate
Ans: C … Ref: 5.1.2.3.3.b.5 … Crit Factors (Wet H2S Dam  Steelmaking) HIC not SSC
2m. Regarding Wet H2S Damage, which statement is FALSE regarding PWHT?
A) PWHT is highly effective in preventing SSC by reduction of both hardness and residual stress
B) PWHT is somewhat effective in reducing SOHIC that is driven by localized stresses
C) Blisters and HIC damage develop without applied or residual stresses
D) Blisters and HIC damage can be prevented by PWHT
Ans: D … Ref: 5.1.2.3.3.b.6 … Crit Factors (Wet H2S Dam  PWHT  No effect on HIC
2n. Regarding Wet H2S Damage, PWHT is not useful for:
A) Carbonate SCC B) Sulfide stress cracking (SSC)

C) Hydrogen-induced Cracking (HIC) D) Amine SCC
Ans: C … Ref: 5.1.2.3.3.b.6 … Crit Factors (Wet H2S Dam  PWHT  No effect on HIC
2o. Blistering, HIC, SOHIC and SSC damage can occur:
A) Anywhere in refinery in a wet H2S environment

B) Anywhere in the refinery where an H2S environment exists
C) Anywhere in the refinery where an H2S environment exists below 300°F (150°C)
D) Anywhere in refinery where H2S environment and applied or residual stresses exist
Answer: A … Ref: 5.1.2.3.4.a … Affected Units (Wet H2S Dam)

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2p. Regarding Wet H2S Damage, Cyanides significantly increase probability & severity of:
A) Blistering only B) Blistering & HIC damage

C) Blistering, HIC and SOHIC damage D) Blistering, HIC, SOHIC & SSC damage
Answer: C … Ref: 5.1.2.3.4.c … Affected Units (Wet H2S Dam)
2q. Regarding Wet H2S Damage, SSC is most likely found in any of these items EXCEPT:
A) In high strength components (such as bolting) B) Hard welds and hard HAZs
C) 300 Series SS valve trim D) Relief valve springs
Answer: C … Ref: 5.1.2.3.4.d … Affected Units (Wet H2S Dam)  400 series SS valve trim
2r. What NDT method requires the least amount of preparation to find Wet H²S cracking?
A) SWUT B) WFMT C) PT D) ACFM
Answer = D … See Para. 5.1.2.3.7.a (Inspection and Monitoring)
Task: Read NACE RP0296 Section 3 (Inspection for Cracking & Section 3.8.5)
3.8.5.1 ACFM is an electromagnetic technique that can be used to detect and size surface breaking cracks
in ferrous materials. The method can be applied through thin coatings and does not require extensive
surface preparation. 3.8.5.2 ACFM is best used as a screening tool for rapid detection of cracking
along welds and/or HAZs with little or no surface preparation. It can be used in lieu of WFMT.
http://www.mistrasgroup.com/services/advancedndt/acfm.aspx …  ACFM information
2s. Inspection for Wet H²S damage generally focuses on:
A) All internal welds B) Trays and down comers

C) Weld seams and nozzles D) Any identified high stress areas
Answer: C … Ref: 5.1.2.3.7.b … Inspection & Monitoring
2t. Regarding Wet H²S damage, Inspection to determine crack depth include all of these
EXCEPT:
A) SWUT for crack sizing B) Grinding out the crack to find the depth
C) Thermal arc gouging removal of the crack D) Acoustic Emission Testing (AET)
Answer = D … See Paragraph 5.1.2.3.7.d/e  Inspection & Monitoring

RETEST UNTIL YOU SCORE ABOVE 90%

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DM # 3 … CREEP/STRESS RUPTURE  12 Q&A

3a. Which statement regarding CREEP is FALSE?
A) Creep is a time dependent deformation of stressed (under load and temperature) components
B) At hi-temps metals can slowly and continuously deform under load below the yield stress
C) Creep deformation leads to damage that may eventually lead to a rupture
D) Creep damage and creep cracking does not affect all materials
Answer: D … Ref: 4.2.8.1.a/b … D of D & Affected Matl’s (Creep)  Affects all materials
3b. Depending on the material, remaining life (RL) for creep damage can be reduced in
half by increasing stress 15% or increasing temps (above maximum design) by as little as:
A) 25°F (12°C)
B) 50°F (27°C)
C) 75°F (40°C)
D) 100°F (55°C)
Answer: A … Ref: 4.2.8.3.a … Critical Factors (Creep)  Interesting fact about Creep)
Comment: RT reports Hydrogen Reformer Tubes (HK 40 or 25%Cr35Ni) that ½ life = +50F over design
3c. Lower temperature threshold for creep damage for CS (less than or equal to 60 ksi) is:
A) 650°F (343°C)
B) 700°F (371°C)
C) 750°F (399°C)
D) 800°F (427°C)
Answer: A … Ref: 4.2.8.3.b & Table 4-3 … Critical Factors (Creep)  Threshold Tables
3d. Lower temperature threshold for creep damage for these materials respectively is:
Given: CS (Greater than or 60 ksi), Low alloy steel 1-1/4 Cr or 2-1/4 Cr-1Mo (normalized),
and lastly SS (Type 316 or 321)
A) CS = 650°F (343°C), Low Alloy steel = 800°F (427°C), SS = 900°F (482°C)

B) CS = 650°F (343°C), Low Alloy steel = 800°F (427°C), SS = 1000°F (538°C)
C) CS = 700°F (371°C), Low Alloy steel = 800°F (427°C), SS = 1000°F (538°C)
D) CS = 700°F (371°C), Low Alloy steel = 800°F (427°C), SS = 900°F (482°C)
Answer: C … Ref: 4.2.8.3.b & Table 4-3 … Critical Factors (Creep)  Threshold Tables

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3e. Regarding creep, the life of metal components becomes nearly infinite at:
A) Temperatures below creep threshold limits for a given material

B) Temperatures at or slightly above creep threshold limits for a given material
C) Temperatures within the creep threshold range limits for a given material family
D) None of these is correct (All materials are susceptible to creep)
Answer: A … Ref: 4.2.8.3.d … Critical Factors (Creep)  Threshold Limit Fact
3f. The appearance of Creep damage with little or no apparent deformation usually:
A) Indicates that a material has low creep ductility

B) Is less severe for higher tensile strength materials and welds
C) Is more likely in fine-grained materials than coarse-grained materials
D) Is more common at higher temps in the creep range or higher stresses in the upper creep range
Answer: A … Ref: 4.2.8.3.e/f … Critical Factors (Low Creep Ductility)
3g. Regarding Low Creep ductility, which statement is FALSE?
A) It is more common at lower temps in the creep range or low stresses in the upper creep range
B) PWHT at lower temps can minimize creep cracking of materials having low creep ductility
C) It is more likely in coarse-grained materials than fine-grained materials
D) It is more severe for higher tensile strength materials and welds
Ans: B … Ref: 4.2.8.3.f & 4.2.8.6.b - Creep  CF & Prevention PWHT @ Higher Temps
3h. Regarding Creep damage (appearance and morphology), which statement is FALSE?
A) In Vessels, cracking occurs where high metal temps and stress concentrations occur together
near major structural discontinuities (pipe tee joints, nozzles, weld flaws)
B) Creep voids initially appear at grain boundaries and after time form fissures and finally cracks
C) Initial stage of damage can only be identified by scanning electron microscope metallography
D) Creep cracking once initiated is time dependent on stress and does not progress rapidly
Answer: D … Ref: 4.2.8.5.a/b/c … Creep  Appearance & Morph  Can progress rapidly

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3i. Which of these Pressure Vessel materials are particularly prone to low creep ductility?
A) High tensile strength CS

B) 1 Cr – 0.5 Mo & 1.25 Cr – 0.5 Mo
C) 2-1/4Cr-1Mo – Quenched & Tempered
D) Type 304 & 304H Austenitic Stainless Steel
Answer: B … 571 Par. 4.2.8.6.b/4.2.8.7.b…Creep  Prev/Mitigation & Insp & Monitoring
3j. Which Inspection & Monitoring techniques should be employed to DETECT CREEP?
A) A combination of techniques (UT, RT, EC, dimensional measurements and replication)

B) Destructive sampling and metallographic examination are required
C) VT, PT or WFMT on several-year intervals & UT (shear wave)
Answer: A … Ref: 4.2.8.7.a/b … Creep  Insp & Monitoring  DETECT/FIND CREEP
3k. Which Insp & Monitoring techniques should be employed to CONFIRM CREEP?
A) A combination of techniques (UT, RT, EC, dimensional measurements and replication)

B) Destructive sampling and metallographic examination are required
C) VT, PT or WFMT on several-year intervals & UT (shear wave)
Answer: B … Ref: 4.2.8.7.a/b … Creep  Insp & Monitoring  CONFIRM CREEP
3l. Which item is NOT correct practice to use on Fired heater tubes when inspecting them
for evidence of overheating, corrosion, and erosion (Creep related damage)?
A) Check for evidence of diametric growth (creep) with a strap or go/no go gauge, and in limited
cases by metallography on in place replicas or take tube samples (destructive testing)
B) Specific tube material retirement criteria considers two factors (diametric growth & wall loss)
C) Employ UT thickness of selected heater tubes where wall losses are most likely
D) VT examine tubes for bulging, blistering, cracking, sagging and bowing
Answer: B … Ref: 4.2.8.7.c … Creep  Insp & Monitoring  Heater Tubes  Operating
Conditions are also critical for retirement criteria  Integrity Operating Windows (IOWs)
End of DM # 3  How did you do on these 12 questions?

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DM # 4 … Hi-Temp H²/H²S Corr  11 Q&A

4a. Hi-Temp H2/H2S Corrosion is closely related to and is a form of:
A) Hydrogen damage B) Wet H2S damage

C) Carburization D) Sulfidation
Answer = D … See Para. 5.1.1.5.1 & 5.1.1.5.4.a (D of D) … SEE SULFIDATION = DM #1
4b. Hi-Temp H2/H2S Corrosion (Sulfidation) occurs at temperatures above:
A) 500°F (260°C) B) 700°F (370°C)

C) 900°F (482°C) D) 1000°F (538°C)
Answer = A … See Paragraph 5.1.1.5.1 (Description of Damage)
4c. Hi-Temp H2/H2S Corrosion usually results in uniform thickness loss associated with:
A) Hot circuits (Sulfur Refining Units) B) Hot circuits in Hydroprocessing Units

C) Hot circuits (Catalytic Reforming Units) D) None of these
Answer = B … See Para. 5.1.1.5.1 & 5.1.1.5.4.a (Description of Damage & Affected Units)
4d. Major factors affecting Hi-Temp H2/H2S Corrosion (a form of Sulfidation) are
temperature (obviously) and:
A) The concentration of H²S and alloy composition

B) Concentration of H²S, alloy composition & velocity of process stream
C) The presence of hydrogen, concentration of H²S and alloy composition
D) None of these
Answer: C … Ref: 5.1.5.5.3.a  High Temp H2/H2S Corrosion … Critical Factors
4e. Which Curves are utilized to determine High Temp H2/H2S corrosion rates?
A) Couper-Gorman B) McConomy C) Nelson D) None of these
Answer = A … Ref: 5.1.1.5.3.c & Fig. 5-8 Couper-Gorman Curves & 4.4.2.6.a …
4f. When comparing Hi-Temp H2/H2S Corrosion rates (due to Sulfidation) in gas oil
desulfurizers/hydrocrackers (compared) to naphtha desulfurizers, which statement is true:
A) Higher corrosion rates exist in gas oil desulfurizers/hydrocrackers by a factor of almost 2

B) Higher corrosion rates exist in gas oil desulfurizers/hydrocrackers (additional 25 – 50%)
C) Higher corrosion rates exist in naphtha desulfurizers by a factor of almost 2
D) None of these
Answer = A … See Para. 5.1.1.5.3.d (Critical Factors)

14
DM # 4 … Hi-Temp H²/H²S Corr  11 Q&A

4g. Regarding Critical Factors for High Temp H²/H²S Corrosion, which statement is false?
A) Corrosion rates of gas oil desulfurizers are twice that found in naphtha desulfurizers
B) Sulfidation rates increase with increasing H²S concentration & with increasing temps
C) Major factors are temp, presence of hydrogen, H²S concentration & alloy composition
D) Increasing chromium content improves resistance if 3 – 5% Cr is used in the LA steels
Ans: D … Ref: 5.1.1.5.3.j  7 – 9 %  DM usually above 140°F (60°C) … CF
4h. Increasing chromium content in Low alloys improves Hi-Temp H2/H2S Corrosion
(Sulfidation) resistance if the chromium content is increased to:
A) 3-5% B) 5-7% C) 7-9% D) 12%
Answer = C … Ref: 5.1.1.5.4.f & Fig. 5-9 Couper Gorman Curves + Table (Rate Reduction)
Note: Curves must be understood as well as the need to increase Cr% & use IOWs
4i. Hi-Temp H2/H2S Corrosion affecting Carbon Steels usually appears as:
A) General or localized pitting

B) Localized pitting accompanied by formation of iron sulfide scale
C) Uniform loss of thickness accompanied by formation of iron sulfide scale
Answer = C … Ref: 5.1.1.5.5.a … Appearance Hi-Temp H2/H2S Corrosion
4j. Hi-Temp H2/H2S Corrosion results is iron sulfide scale that is:
A) Accompanied by general or localized pitting in areas without any scale

B) About 5 times the volume of any lost metal and may be in multiple layers
C) Uniform loss of thickness accompanied by formation of iron sulfide scale
D) Shiny and gray and attached to the metal surface and is very easily detected
Answer = B … Ref: 5.1.1.5.5.a/b/c … Appearance  Hi-Temp H2/H2S Corrosion
4k. Hi-Temp H2/H2S Corrosion Monitoring & Inspection methods do NOT include:
A) UT, VT and RT thickness readings are used to monitor loss in thickness

B) Actual operating temperatures should be verified in the field to compare against design
C) Periodical process simulations should check/confirm H2S levels are not greatly increased
D) Strategically placed corrosion coupons to provide additional info on damage rate and extent
Answer = D … Ref: 5.1.1.5.7.a/b/c … Insp & Monitoring  Hi-Temp H2/H2S Corrosion

15
DM # 5 … PASCC (Polythionic Acid SCC)  6 Q&A

5a. A form of SCC normally occurring during shutdowns, startups or during operation
when cracking is due to sulfur acids forming from sulfide scale, air and moisture acting on
sensitized stainless steel is called:
A) Caustic SCC B) Chloride SCC
C) Polythionic acid SCC (PASCC) D) Flue Gas Dew Point Corrosion
Answer: C … Ref: 5.1.2.1.1.a … Description of Damage  PASCC
5b. In order for PASCC to occur the material must be:

A) PWHT’d B) Non-PWHT’d C) Sensitized D) Austenitic SS
Ans: C … Ref: 5.1.2.1.2/5.1.2.1.3.a.ii (Alloy 600/800) … Affected Materials & CF …
Sensitization occurs between 750°F – 1500°F (400°C – 815°C)
5c. Where is PASCC normally located?
A) Typically located adjacent to welds B) Typically located in the base metal
C) Typically located at stress risers only D) None of the above are correct
Answer: A … Ref: 5.1.2.1.1.b & 5.1.2.1.5.a  Figure 5-12 … D of D & Appearance
5d. PASCC results when SS materials have been sensitized over time (how) and at what
temperature?
A) Carbon diffuses into metal grain boundaries above 1000°F (538°C)
B) Chromium carbide formation in metal grain boundaries above 1000°F (538°C)
C) Carbon diffuses into metal grain boundaries from 750 to 1500°F (400 to 815°C)
D) Chromium carbide formation in metal grain boundaries from 750 to 1500°F (400 to 815°C)
Answer = D … See Paragraph 5.1.2.1.3.b  Critical Factors
5e. Which of these SS materials are more susceptible to PASCC?

A) 304 & 304H B) 304L & 316L C) Super austenitic SS D) Duplex SS
Answer = A … See Paragraph 5.1.2.3.c  Critical Factors
5f. PASCC may be referred to as any of these EXCEPT:
A) PTASCC B) IGSCC C) IGC D) IGA
Answer = B … See Paragraph 5.1.2.1.8 & Figure 5-13  Related Mechanisms
5g. PASCC may be prevented by following the guidelines in:
A) NACE RP0169 B) NACE RP0170 C) API 751 D) None of these
Answer = B … See Paragraph 5.1.2.1.6.a  Prevention
5h. PASCC can be an inspection challenge because:
A) Of the high temperatures involved B) Cracking may not occur till well into turnaround
C) Of the difficulty of performing PT exams D) None of these
Answer = B … See Paragraph 5.1.2.1.7.b  Insp & Monitoring
16
DM # 6 … NAC (Naphthenic Acid Corr)  11 Q&A

6a. Which of these is NOT a Critical factors for NAC?
A) Sulfur promotes iron sulfide formation and has an inhibiting effect on NAC, up to a point,
and naphthenic acids remove protective iron sulfide scales on the surface of metals
B) NAC is a function of naphthenic acid content (neutralization number), temperature, sulfur
content, velocity and alloy composition.
C) Neutralization # or Total Acid Number (TAN) is a measure of acidity (organic acid content)
D) Severity of corrosion decreases with increasing acidity of the hydrocarbon phase
Answer = D …Ref: 5.1.1.7.3.a/b/c/g/h NAC … Severity of corr. increases (Crit Factors)
6b. What alloying element will be the most effective in improving resistance to NAC?
A) Chrome B) Nickel C) Niobium D) Molybdenum
Answer = D … See Para. 5.1.1.7.3.L (Critical Factors) & also Para. 5.1.1.7.6.c (Prevention)
Note: Table 5-2 also applies  THIS IS A MUST KNOW ITEM FOR EXAMS
6c. NAC can be a particular problem with very low sulfur crudes with TANs as low as:
A) 0.10 B) 0.20 C) 1.0 D) 2.0
Answer: A …Reference: 5.1.1.7.3.i  NAC by the numbers (Critical Factors)
6d. Which of these if FALSE regarding temperatures associated with NAC?

A) NAC can occur at temperatures as low as 350°F (177°C)
B) NAC normally occurs in hot streams above 500°F (260°C)
C) Severity of NAC increases with temperature up to about 750°F (400°C)
D) NAC has been observed in hot coker gas oil streams up to 800°F (427°C)
Answer: B …Ref: 5.1.1.7.3.j  NAC  (Critical Factors)  425°F (218°C) is correct
6e. What percentage of Molybdenum as an alloying element provides improved corrosion

resistance to NAC, this depending on the TAN of the whole crude and its side cuts?
A) ≤ 0.5% Molybdenum B) ≤ 1.25% Molybdenum

C) 1 % to 2 % Molybdenum D) 2% to 2.5% Molybdenum
Answer = D …Reference: 5.1.1.7.3.L  NAC by the numbers (Critical Factors)
6f. NAC is most severe in which phase of flow?
A) Vapor B) Liquid C) Two phase (Liquid & Vapor) D) None of these
Answer = C … See Paragraph 5.1.1.7.3.m  Critical Factors

17
DM # 6 … NAC (Naphthenic Acid Corr)  11 Q&A

6g. NAC is most severe in all of the following areas EXCEPT:
A) In distillation towers where hot vapors condense to form liquid phase droplets
B) Hot hydrocarbon streams upstream of the crude and vacuum units
C) In areas of high velocity or turbulence
D) Two phase (liquid and vapor) flow
Answer: B …Reference: 5.1.1.7.3.m  NAC … (Critical Factors … And Affected Units)
6h. For improved resistance to NAC, which increase in alloys should be used?
A) Higher Cr% B) Higher C%

C) Higher Moly% D) Higher Nickel%
Answer: C … Ref: 5.1.1.7.6.c & Table 5-2 NAC … Appearance or MOD
6i. The appearance of NAC may be characterized by any of these EXCEPT:
A) Flow induced grooving in high velocity

B) Localized corrosion
C) General corrosion
D) Pitting corrosion
Answer: C …Reference: 5.1.1.7.5.a  NAC … (Appearance & Morphology)
6j. Which of these statements regarding Inspection & monitoring of NAC is TRUE?
A) UT is used for locating/thickness monitoring of NAC and it is often followed by RT
B) RT is used for locating/thickness monitoring of NAC and it is often followed by UT
C) Because NAC localized erosion is difficult to locate, UT is the primary detection method
D) Because NAC general corrosion is relatively uniform, UT is the primary detection method
Answer: B …Reference: 5.1.1.7.7.a/b  NAC … (Inspection and Monitoring)
6k. NAC is difficult to distinguish from this competing damage mechanism (occurs in the
same Units and appears in the same location):
A) Acidic (Sour Water) Corrosion
B) Hydrochloric Acid (HCL) Corrosion
C) Sulfidation
D) Carbolic Acid (Phenol) Corrosion
Answer: C …Reference: 5.1.1.7.8  NAC & Sulfidation appear as identical mechanisms

Note: Saudi Aramco claims to have no NAC … Fact is NAC exists and is called Sulfidation

18
DM # 7 Ammonium Bisulfide (Alkaline Sour Water) Corr 8 Q&A
7a. Ammonium Bisulfide Corrosion is also called:
A) Alkaline Sour Water Corrosion

B) Acidic Sour Water Corrosion
C) Ammonia SCC
D) Ammonium Chloride Corrosion
Answer = A …Ref: 5.1.1.2  Ammonium Bisulfide (Alkaline Sour Water) Corrosion
7b. Aggressive localized corrosion occurring in hydroprocessing reactor effluent streams

and in units handling alkaline sour water that has caused several major failures is called:
A) Ammonia SCC
B) Sour Water Corrosion
C) Ammonium Bisulfide Corrosion
D) Ammonium Chloride Corrosion
Answer = C …Ref: 5.1.1.2.1.a/b  Ammonium Bisulfide (Alkaline Sour Water) Corrosion
7c. Which statement is FALSE regarding Ammonium Bisulfide Corrosion critical factors?
A) NH4HS concentration, H2S partial pressure, velocity and/or localized turbulence, pH,
temperature, alloy composition and flow distribution are critical factors
B) NH4HS salt deposits lead to localized under deposit corrosion (especially low velocity areas)
C) NH4HS deposits may cause fouling and plugging unless flushed away with wash water
D) NH4HS salts are corrosive and if hydrated (when flushed) they become less corrosive
Ans = D …Ref: 5.1.1.2.3.a/c/d & 5.1.1.2.5.b  Amm Bisulf Corr  Salts not corrosive
unless hydrated … Wetted Deposits cause localized corrosion when not washed away 100%
7d. Ammonium Bisulfide Corr occurs when Nitrogen is converted to Ammonia & reacts
with H2S to form NH4HS salts that precipitate out of gas phase in reactor effluent streams:
A) At temps above 500°F (260°C)

B) At temps below 350°F (177°C)
C) At temps below 150°F (66°C)
Answer = C …Ref: 5.1.1.2.3.c & 5.1.1.2.4.a  Amm. Bisulf. Corr  150F or 66°C Rule

19
DM # 7 Ammonium Bisulfide (Alkaline Sour Water) Corr 8 Q&A

7e. Ammonium Bisulfide solutions becomes increasingly corrosive when:
A) Below 1 wt % NH4HS
B) Below 2 wt % NH4HS
C) Above 1 wt % NH4HS
D) Above 2 wt % NH4HS
Answer = D …Ref: 5.1.1.2.3.b / 5.1.1.2.5  Ammonium Bisulfide Corr  Above 2 – 8 wt %
7f. To prevent Ammonium Bisulfide Corr in CS, what velocities should be maintained in
Carbon Steel as per Industry guidelines?
A) 2 to 4 fps B) 2 to 8 fps
C) 4 to 12 fps D) 10 to 20 fps
Answer = D …Ref: 5.1.1.2.6.c  Amm Bisulf Corr (Alkaline Sour Water Corr)  Prev
7g. Which of these is NOT an Insp & Monitoring strategy for Ammonium Bisulfide Corr?
A) Carefully designed plan (Input from Process/Materials/Corr engineers) to determine specific

areas of vulnerability and determine ammonium bisulfide content by sampling and calculations
B) Frequent UT scanning and/or RT profile thickness of high and low velocity areas such as
downstream of control valves at high NH4HS concentrations
C) ACFM and especially EC inspection of carbon steel air cooler tubes
D) Monitor water injection facilities and flow meters to ensure proper operation
Answer = C …Ref: 5.1.1.2.7.a/b/c/d Amm Bisulf Corrosion  Insp & Monitoring
7h. Which of the following is the best Insp & Monitoring NDE strategy for Ammonium
Bisulfide (Alkaline Sour Water Corrosion)?
A) Regular program of UT or profile RT similar to an Injection Point Program strategy

B) Regular program of UT or profile RT at dead legs and at other areas of low velocity
C) Frequent UT scanning and/or RT profile thickness of high and low velocity areas
D) Frequent UT scanning and/or RT profile thickness of low velocity areas
Answer = C …Ref: 5.1.1.2.7.a/b/c/d Ammonium Bisulfide Corrosion  Insp & Monitor

20
DM # 8 … Ammonium Chloride Corrosion  5 Q&A

8a. The primary cause of Ammonium Chloride Corrosion is the formation of salts from:
A) Stagnant flow (low velocity) B) Water washing without a steam out
C) Steam out without first water washing D) Cooling of process streams (precipitation)
Answer = D … See Para. 5.1.1.3.3.a/b  Ammonium Chloride Corrosion (Critical Factors)
8b. Ammonium Chloride Corrosion, depending upon the concentration of NH³ and HCL,
may corrode piping and equipment at temperatures:
A) Well above the water dew point, greater than 300°F (149°C)
B) At temps up to 150°F (66°C), when salts are precipitated
C) At temps up to 250°F (121°C)
Answer = A …Ref: 5.1.1.3.3.b  Ammonium Chloride Corrosion (Critical Factors)
8c. Which of these is FALSE regarding Ammonium Chloride (Corrosion) salts?

A) Salts are hygroscopic & readily absorb water (This can leads to corrosion >100 mpy)
B) When salts deposit above water dewpoint, water wash injection may be required
C) Salts are highly corrosive and form an acidic solution when mixed with water
D) Corrosion rates decrease with increasing temperatures?
Answer = D? …Ref: 5.1.1.3.3.c/d/e/f  Ammonium Chloride Corrosion (Critical Factors)
8d. Ammonium Chloride (Corrosion) results in (what appearance and type of corrosion):
A) Whitish, greenish or brownish salts and corrosion under salts results in localized pitting
B) Whitish or brownish salts and corrosion under salts results in general uniform thinning
C) White salts and corrosion where salts do not cover surfaces results in localized pitting
D) White salts and corrosion where salts do not cover surfaces results in general thinning
Answer: A … Ref: 5.1.1.3.5.a/b/c  Ammonium Chloride Corr … Appearance or MOD
8e. Ammonium Chloride (Corr) Insp/Monitoring strategies include all of these EXCEPT:
A) RT or UT thickness monitoring are used to determine remaining wall thickness
B) Monitoring feed streams & effluent waters closely for ammonia & chlorides present
C) Temperature monitoring and controls to maintain metal temps below salt deposition temps
D) Deposits are likely when pressure drops increase or X-Chgr thermal performance deteriorates
Answer: C … Ref: 5.1.1.3.7.a/b/c/d/e  Ammonium Chloride Corr … Insp & Monitoring

is needed to maintain metal temps ABOVE salt deposition temps

21
DM # 9 … HCL Corrosion  10 Q&A

9a. Hydrochloric acid (aqueous HCl) in a very wide range of concentrations causes:
A) General corrosion that is very aggressive to both CS & Low alloy steel
B) Localized corrosion that is very aggressive to both CS & Low alloy steel
C) General & localized corrosion that is very aggressive to CS, Low alloy steel and SS
D) General & localized corrosion very aggressive to most common refinery construction mat’ls
Answer: D … Ref: 5.1.1.4.1.a … HCL Corrosion Description of Damage
9b. Which of these is FALSE regarding Hydrochloric acid Corrosion damage in refineries?
A) Water droplets condensing can be highly acidic and promote high corrosion rates
B) Damage in refineries is most often associated with condensed salt deposit corrosion
C) Damage occurs when vapors containing water & HCl condense from the overhead stream
D) Damage affects overhead streams above Crude distillation, fractionation and stripping towers
Answer: B … Ref: 5.1.1.4.1.b … HCL Corr Description of Damage  Dew Point Corr
exists in vapor condensing conditions and condensed water droplets become highly acidic
9c. Regarding Hydrochloric acid Corrosion, which of these are critical factors?
A) HCl acid concentration, temperature and alloy composition

B) HCl acid and water concentrations, temperature and alloy composition
C) HCl acid and water and salt concentrations, pH, temperature and alloy composition
Answer: A … Ref: 5.1.1.4.3.a … HCL Corr  Critical Factors.
9d. The severity of Hydrochloric acid (HCl) Corrosion will:
A) Decreases with increasing HCl concentrations and decreasing temperatures

B) Decreases with increasing HCl concentrations and increasing temperatures
C) Increases with increasing HCl concentrations and decreasing temperatures
D) Increases with increasing HCl concentration and increasing temperatures
Answer: D … Ref: 5.1.1.4.3.b … HCL Corr  Critical Factors
9e. Carbon steel and low alloy steels are subject to excessive hydrochloric acid corrosion
when exposed to any concentration of HCl acid that produces a pH below:
A) 2.5 B) 4.5
C) 5.5 D) 7.0
Answer: B … Ref: 5.1.1.4.3.d … HCL Corr  Critical Factors

22
DM # 9 … HCL Corrosion  10 Q&A

9f. Which materials have the best resistance against Hydrochloric Acid (HCl) Corrosion?
A) Carbon steel and Low alloy Steels B) 300 series SS & 400 series SS
C) Nickel-based alloys D) Copper Alloys
Answer = C … See Para 5.1.1.4.3.e/f  HCL Corr  Critical Factors  Never use SS 
Note: 300 & 400 series SS are not usefully resistant to HCl at any concentration or temp
9g. Refinery Units where HCl acid corrosion is found include which of these?
A) Hydroprocessing units, catalytic reformer units, alkylation units & crude units
B) Hydroprocessing units, catalytic reformer units, amine units & vacuum units
C) Hydroprocessing units, catalytic reformer units, vacuum units & crude units
D) Hydroprocessing units, catalytic reformer units, amine units & crude units
Answer: C … Ref: 5.1.1.4.4 in 1st Para. & 5.1.1.4.6 … HCL Corr Affected Units or Equip
9h. HCl acid corrosion damage can appear as any of these EXCEPT:
A) CS & LA steels can suffer general uniform thinning, localized corr and under deposit attack
B) Carbon steel and low alloy steels can suffer stress corrosion cracking (SCC)
C) 300 Series SS may experience chloride stress corrosion cracking
D) 300 Series SS and 400 Series SS will often suffer pitting attack
Answer: B … Ref: 5.1.1.4.5.a/b … HCL Corrosion Appearance
9i. HCl acid corrosion damage in locally thinned areas can be best detected by:
A) Profile radiography
B) VT where possible and UT thickness readings
C) Automatic ultrasonic scanning methods or profile radiography
D) Strategically placed corrosion probes & UT thickness readings
Answer: C … Ref: 5.1.1.4.7.a/c … HCL Corrosion  Inspection & Monitoring
9j. Which of these are important aspects of a well-developed program to minimize the
effects of HCl corrosion?
A) Establishing IOWs B) Process and Corrosion monitoring

C) Strategically placed corrosion probes/coupons D) None of these are correct
Answer: B … Ref: 5.1.1.4.7.a/c … HCL Corrosion  Inspection & Monitoring

23
DM # 10 – HTHA (Hi-temp hydrogen attack)  8 Q&A
10a. HTHA results from exposure to hydrogen at elevated temperatures & pressures when
hydrogen reacts with carbides in steel to form this gas that cannot diffuse through the steel:
A) H2S
B) NH4HS
C) CH4
D) None of these
Answer: C … Ref: 5.1.3.1.1.a  Methane = CH4 … HTHA  Description of Damage
10b. Regarding HTHA, hydrogen at elevated temps/pressures reacts with which elements
to form this gas that cannot diffuse through steel, causing an overall loss in strength?
A) Hydrogen dioxide in steel to create oxidation and damage

B) Hydrogen dioxide in steel to create H²S and the damage
C) Carbides in steel to form methane (CH4) and damage
D) Carbides in steel to create oxidation and damage
Answer: C … Ref: 5.1.3.1.1.a  Methane = CH4 … HTHA  Description of Damage
10c. Regarding HTHA, which of these are critical factors for a specific material?
A) Temperature, H2S concentrations, pressure, time and stress

B) Temperature, hydrogen partial pressure, time and stress
C) Temperature, H2S concentrations, time and stress
Answer: B … Ref: 5.1.3.1.3.a … HTHA Corr  Critical Factors.
10d. What chrome moly combinations are not susceptible to HTHA at conditions normally
seen in refinery units?
A) At least 1.25% Cr and ½ % Moly

B) At least 2.25% Cr and 1% Moly
C) At least 5% Cr and 1% Moly
D) At least 7% Cr and 1% Moly are not susceptible
Answer: C … Ref: 5.1.3.1.2 & 5.1.3.1.3.f … Affected Materials & Critical Factors

24
DM # 10 – HTHA (Hi-temp hydrogen attack)  8 Q&A
10e. Which of these mechanisms is difficult to distinguish from HTHA in the early stages?
A) Wet H2S Damage (Blistering & HIC)

B) Hi-Temp H2/H2S Corrosion
C) Sulfidation
D) Creep
Ans: D … 571 Par. 5.1.3.1.5 …HTHA in early stages is difficult to distinguish from CREEP
NOTE: A MUST KNOW EXAM QUESTION THAT APPEARED ON 2010+ EXAMS
10f. Due to HTHA considerations, what steel alloy is no longer recommended for new
construction in hot hydrogen services?
A) Mn ½ Mo
B) C – 0.5 Mo
C) 1Cr ½ Mo
D) 1¼ Cr ½ Mo
Answer = B … See Paragraph 5.1.3.1.6.c&d below  HTHA  Prevention/Mitigation
10g. Which Curves are utilized to determine safe operation regarding HTHA?
A) Couper-Gorman curves per API 939-C

B) McConomy curves per API 939-C
C) Nelson curves per API 941
D) Melon curves per API 583
Answer = C … Ref: 5.1.3.1.3.d & Fig. 5-56 Nelson Curves  MUST KNOW API 941
10h. HTHA damage is usually detected (determined) by which of the following methods?
A) UT techniques (velocity ratio & AUBT)

B) MT or PT
C) WFMT
D) RT
Answer = A … See Paragraph 5.1.3.1.7.b  Inspection & Monitoring

25
DM # 11 … OXIDATION  5 Q&A
11a. OXIDATION is when oxygen reacts with steel at high temps to:
A) Convert metals to oxide scale using oxygen (approximately 20%) present in surrounding air
B) Corrode metals using oxygen and other combusted gases at a variety of concentrations
C) Corrode metals using oxygen at temperatures exceeding 1200°F (649°C)
Answer = A … See Para. 4.4.1.1.a/b  Oxidation  Description of Damage
11b. OXIDATION of Carbon Steel (rates of metal loss) begins to become significant above:
A) About 750°F (400°C) B) About 900°F (482°C)
C) About 1000°F (538°C) D) About 1200°F (649°C)
Answer = C … See Para. 4.4.1.3.b  Oxidation  Critical Factors  1000°F Rule for CS
11c. OXIDATION (metal loss by scaling) does not usually occur in 300 Series SS until
temperatures reach:
A) Above 1000°F (538°C)
B) Above 1200°F (649°C)
C) Above 1500°F (816°C)
D) 300 Series SS will not scale as failure is by decarburization
Answer = C … See Para. 4.4.1.3.c  Oxidation  Critical Factors  1000°F Rule for CS
11d. Resistance to OXIDATION is best achieved by increasing the percentage of this alloy?
A) Nickel B) Chrome C) Molybdenum D) Silicon
Answer = B … See Para. 4.4.1.3.c  Oxidation  Critical Factors  Chrome percentage
11e. Oxidation damage is usually determined by which of these methods?

A) UT Thickness B) VT of affected surfaces
C) MT or PT and UT thickness exams D) Thermocouples
Answer = A … See Paragraph 4.4.1.7.c  Inspection & Monitoring
11f. Regarding Oxidation damage, temps are usually monitored by which of the methods?
A) UT Thickness
B) VT of affected surfaces
C) MT or PT and UT thickness exams
D) Tube skin thermocouples or Infrared Thermography
Answer = D … See Paragraph 4.4.1.7.b  Inspection & Monitoring

26
DM # 12 … THERMAL FATIGUE  10 Q&A

12a. Which Mechanism is the result of cyclic stress caused by temperature variations?
A) Creep B) Thermal Fatigue

C) Cyclic Cracking D) SCC
Answer: B … Reference: 4.2.9.1  Thermal Fatigue … Description of Damage
12b. Key factors affecting Thermal Fatigue are:
A) The magnitude of the temperature swing and frequency (number of cycles)

B) The magnitude of the temperature swing and the time in service
C) Temperature, time in service and material
Answer = A … See Paragraph 4.2.9.3.a  Critical Factors
12c. A practical rule for Thermal Fatigue related to temperature is to suspect cracking:
A) Temperatures exceed 500°F (260°C) and time in service is unknown

B) Temperatures exceed 700°F (370°C) and time in service is unknown
C) No set limits or temperature rules apply to Thermal Fatigue
D) When temperature swings (cycles) exceed 200°F (93°C)
Answer = D … See Paragraph 4.2.9.3.c  Critical Factors  200°F (93°C) Rule
12d. Which damage mechanism has been a major problem on coke drum shells, and
particularly in the area of the supporting skirt near the shell?
A) Thermal fatigue
B) Erosion/Corrosion
C) 885°F Embrittlement
D) Temper embrittlement
Answer: A … Ref: Par. 4.2.9.4.b & Figs. 4-12/4-13 … Affected Units or Equipment
Thermal Fatigue (coke drums) has 2 figures & is also found in the PFDs in Fig. 5-43
12e. Steam actuated soot blowers may cause this damage mechanism if the first steam
exiting the soot blower nozzle contains condensate. What is the damage mechanism?
A) CO² Corrosion
B) Erosion/Corrosion
C) Condensate Corrosion
D) Thermal Fatigue
Answer = D … See Para. 4.2.9.4.e  Thermal Fatigue  Affected Units or Equipment

27
DM # 12 … THERMAL FATIGUE  10 Q&A

12f. Which statement best suits Thermal fatigue crack propagation & appearance?
A) Axial to the stress & cracks are branching and transgranular

B) Transverse to the stress & cracks are usually branching and transgranular
C) Axial to the stress & cracks are dagger shaped, transgranular & oxide-filled
D) Transverse to stress & cracks are usually dagger shaped, transgranular & oxide-filled
Answer: D … Ref: 4.2.9.5.b & Fig. 4-14 …  Thermal Fatigue  Appearance & MOD
12g. Which statement is FALSE regarding appearance / morphology of Thermal fatigue?

A) Cracks propagate transverse to the stress and may appear as single or multiple cracks
B) Cracks are generally wide and filled with oxides due to the elevated temperatures
C) Cracks are usually transgranular with a spider web appearance
D) Cracks usually initiate on the surface of the component
Ans: C … Ref: 4.2.9.5.a/b  Thermal Fatigue  Appearance & MOD
12h. Thermal fatigue is best prevented:

A) By good design
B) By good operating practices (especially startup & shutdown)
C) Through design and operation to minimize thermal stresses and thermal cycling
Ans: C … Ref: 4.2.9.6.a  Thermal Fatigue  Prevention
12i. Best way to prevent Thermal Fatigue during Operational Start-up & Shut Down is:
A) Use good design to eliminate stress

B) Control rates of heating & cooling
C) Monitor thermal expansion
Answer = B … See Paragraph 4.2.9.6.a.ii  Prevention  Thermal Fatigue
12j. Effective inspection methods to employ for Thermal Fatigue:
A) Perform Visual examination, MT and PT as cracking is usually surface connected

B) Monitor controlled rates of heating & cooling
C) Monitor thermal expansion and cycling
Answer = A … See Paragraph 4.2.9.7.a  Insp & Monitoring  Thermal Fatigue
End of DM # 12  How did you do on the 10 Qs?

28
DM # 13 … SOUR WATER (ACIDIC) CORR  5 Q&A

13a. Corrosion of steel due to Acidic Sour Water containing H²S tends to occur at:
A) pH > 7 B) pH > 2 C) pH > 3 D) pH > 4.5
Answer = D … See Par. 5.1.1.10.1  … Sour Water (Acidic) Corr … Descrip of Damage
13b. Which of these choices include all critical factors for Sour Water (acidic) corrosion.
A) H2S content, pH, temperature, velocity and oxygen concentration

B) H2S content, pH, temperature and oxygen concentration
C) H2S content, pH, temperature
D) None of these
Answer: A … Ref: 5.1.1.10.3.c  Sour Water (Acidic) Corrosion … Critical Factors
13c. Regarding acidic corrosion, at a given pressure, H²S concentration in sour water
A) Increases as temperature increases B) Increases as temperature decreases

C) Decreases as temperature increases D) Decreases as temperature decreases
Answer: C … Ref: 5.1.1.10.3.c  Sour Water (Acidic) Corrosion … Critical Factors
13d. Which item is FALSE regarding the appearance of Sour Water (acidic) corrosion
damage?
A) Damage typically appears as general thinning

B) Localized corrosion or under deposit attack can occur, especially if CO2 is present
C) Corrosion in CO2 containing environments may also be accompanied by Carbonate SCC
D) 300 Series SS is susceptible to pitting & may experience crevice corrosion & Chloride SCC
Ans: B … Ref: 5.1.1.10.5.a/b  Sour Water (Acidic) Corrosion … App  Oxygen not CO2
13e. Regarding Sour Water (acidic) corrosion damage, which statement is FALSE
regarding Inspection & Monitoring methods?
A) Evidence of locally thinned areas can be found using scanning UT methods or profile RT
B) Process and corrosion monitoring programs are needed to minimize the effects of corrosion
C) Properly placed corrosion probes/coupons provide additional info on rates/extent of damage
D) Water draws (overhead accumulator) should be monitored periodically to measure O2 content
Answer: D … Ref: 5.1.1.10.7.a/b/c  Sour Water (Acidic) Corr … Insp & Monitoring …
Note: Water draws should be monitored for pH, not Oxygen content
End of DM # 13  How did you do on the 5 Qs?

29
DM # 14 … REFRACTORY DEGRADATION … 10 Q&A

14a. Thermal insulating refractories & erosion resistant refractories are susceptible to
various forms of mechanical damage and corrosion from which of these hi-temp DMs?
A) Primarily sulfidation
B) Primarily sulfidation & HTHA
C) Oxidation, Sulfidation and others
D) None of these
Answer: C … API 571, Par. 4.2.18.1 Refractory Degradation … Description of Damage
14b. Thermal insulating refractories & erosion resistant refractories are susceptible to
various forms of mechanical damage that include all of these EXCEPT:
A) Calcining B) Cracking
C) Erosion D) Spalling
Answer: A … API 571, Par. 4.2.18.1 Refractory Degradation … Description of Damage

Note: Calcining or high temp deterioration of outside concrete foundations (turns it to dust)
14c. Select all refractory materials (from those listed) that are affected by degradation:
A) Castable refractories only

B) Ceramic fibers and castable refractories only
C) Ceramic fibers, castable refractories and refractory bricks
D) Ceramic fibers, castable refractories, refractory bricks and plastic refractories
Answer: D … API 571, Para. 4.2.18.2 – Refractory Degradation Question
14d. The key to minimizing refractory damage is to assure:
A) Good design of refractories

B) Good design and proper selection of refractories
C) Good design, proper selection and installation of refractories
D) Good design and quality of refractory and compatibility with damage expected
Answer: C … API 571, Para. 4.2.18.3.a – Refractory Degradation  Critical Factors
14e. Refractory lined equipment should be designed for:
A) Erosion primarily
B) Erosion, thermal shock and thermal expansion
C) Erosion, thermal shock, thermal expansion and oxidation resistance
Answer: B … API 571, Para. 4.2.18.3.b – Refractory Degradation  Critical Factors

30
DM # 14 … REFRACTORY DEGRADATION … 10 Q&A

14f. For Refractory lined equipment, which of these should be in strict accordance with the
manufacturer’s specifications and any ASTM requirements?
A) Application procedures for refractory

B) Application procedures and cure times for refractory
C) Application procedures, cure times and Dry out schedules for refractory
D) Application procedures, cure times, bake out temperatures & Dry out schedules for refractory
Answer: C … API 571, Para. 4.2.18.3.c – Refractory Degradation  Critical Factors
14g. For Refractory lined equipment, which of these is NOT a critical factor for anchors?
A) Anchors must be resistant to condensing sulfurous acids in heaters and flue gas environments
B) Anchor materials must be compatible with thermal coefficients of expansion of base metal
C) Anchors must be resistant to oxidation in high temperature services
D) Anchors must be resistant to hydrogen delayed cracking
Answer: D … API 571, Para. 4.2.18.3.d/e/f – Refractory Degradation  Critical Factors
14h. For Refractory lined equipment, which of these is NOT a critical factor for anchors?
A) Anchors must be resistant to condensing sulfurous acids in heaters and flue gas environments
B) Anchor materials must be compatible with thermal coefficients of expansion of base metal
C) Anchors must be resistant to oxidation in high temperature services
D) Anchors must be resistant to hydrogen delayed cracking
Answer: D … API 571, Para. 4.2.18.3.d/e/f – Refractory Degradation  Critical Factors
14i. Which of these is FALSE regarding the appearance of Refractory degradation?
A) In erosive services, refractory may be washed away or thinned, exposing anchoring systems
B) Refractory may show signs of softening or general degradation from exposure to moisture
C) Coke deposits may develop on refractory surfaces and promote cracking and deterioration
D) Refractory may show signs of excessive cracking, spalling or lift-off from the substrate
Answer: C … API 571, Para. 4.2.18.5.a/b/c – Refractory Degradation  Behind refractory
14j. Which Inspection & Monitoring method is best to identify refractory damage?
A) Conduct visual inspection during operations through peep doors

B) Survey the hot face of refractory Onstream through peep doors using IR to identify hot spots
C) Survey cold-wall equipment Onstream using IRT to monitor hot spots to help identify damage
Answer: C … API 571, Para. 4.2.18.7.a/b – Refractory Degradation  IR Thermography

31
DM # 15 … GRAPHITIZATION  12 Q&A
15a. A change in microstructure of certain CS & 0.5 Mo steels after long-term operation at
800º F to 1100º F (427°C - 593°C) range that may cause a loss in strength, ductility and/or
creep resistance is called:
A) Temper Embrittlement B) Carburization

C) Graphitization D) Creep
Answer: C … Ref: 4.2.1.1.a  Graphitization DOD  0.7% Chrome eliminates Graph
15b. Graphitization is a change in the microstructure of Carbon steels & 0.5Mo steels after
long term operation in what temperature range?
A) About 600°F to 1000°F (316 to 540°C) B) About 650°F to 1070°F (343 to 577°C)
C) About 800°F to 1100°F (427 to 593°C) D) About 850°F to 1400°F (440 to 760°C)
Answer = C … See Para 4.2.3.1 (Description of Dam)  Graphitization Temp Range …

NOTE: A = 885°F Embrittlement, B = Temper Embrittlement, D = Spheroidization
15c. Regarding graphitization, at elevated temperatures, the carbide phases in certain

carbon steels are unstable and may decompose into graphite:
A) Needles B) Dust C) Nodules D) None of these

Answer: C … Ref: 4.2.1.1.b  Graphitization  Description of Damage
15d. The materials that are most susceptible to graphitization are:
A) CS and 0.5 Mo steels B) CS and Cr-Mo steels
C) Stainless steels D) Nickel Steels
Answer = A … See Para. 4.2.1.1.a Graphitization  (D of D) & 4.2.1.2 (Affected Mat’ls)
15e. Most important (critical) factors affecting graphitization are:
A) Chemistry, stress, temperature, and time at exposure

B) Chemistry, stress, temperature, pressure and time at exposure
C) Chemistry, stress, temperature, flow velocity and time at exposure
D) Chemistry, stress, temperature, heat treatment, flow velocity and time at exposure
Ans: A … Ref: 4.2.1.3.a … Graphitization Critical Factors
15f. Weld heat affected zone graphitization is also called:
A) Half-moon Graphitization B) Eyebrow Graphitization

C) Radii Graphitization D) HAZ Graphitization
Answer: B … Reference: 4.1.2.3.f  Graphitization Critical Factors

32
DM # 15 … GRAPHITIZATION  12 Q&A
15g. Which statement is True regarding temperatures & the rate of graphitization?
A) It increases with increasing temperatures above 800°F (427°C)
B) Below 800°F (427°C), the rate of graphitization is extremely fast
C) Above 800°F (427°C), the rate of graphitization is extremely slow
D) It greatly decreases when the temperatures exceed 1100°F (593°C)
Ans: A … Ref: 4.2.1.3.d  Graphitization Critical Factors
15h. Units where graphitization may be suspected include which of the following?
A) FCC and Hydrotreater Units B) FCC, catalytic reforming & coker units
C) FCC, catalytic reforming & Alky units D) None of the above is correct
Answer: B … Ref: 4.2.1.4.a … Graphitization Affected Units or Equipment
15i. Advanced stages of graphitization damage related to loss in creep strength may include
microfissuring/microvoid formation, subsurface cracking or surface connected cracking.
Generally, however, damage due to graphitization is:
A) Highly visible and apparent and can also be observed by metallographic exam in early stages
B) Not visible or readily apparent until the late stages after observation by metallographic exam
C) Not visible or readily apparent and can only be observed by metallographic exam
Answer: C … API 571 … Para. 4.2.1.5 … Graphitization … appearance or morphology
15j. Graphitization can be prevented by using chromium (at least 0.7%) containing low
alloys steels for long-term exposure above:
A) 650º F (343°C) B) 700º F (370°C) C) 750º F (400°C) D) 800º F (427°C)
Ans: D … Ref: 4.2.1.6 … Graphitization Prev/ Mitig … 0.7% Chrome eliminates Graph
15k. Spheroidization and graphitization are competing mechanisms that occur at

overlapping temperature ranges. Spheroidization tends to occur preferentially above this
temperature while graphitization predominates below this temperature:
A) 1000º F (538°C) B) 1025º F (552°C) C) 1050º F (565°C) D) 1100º F (593°C)
Answer: B … Ref: 4.2.1.8  Competing DMs … Graphitization Related Mechanisms
15L. Graphitization is best identified by which of these Inspection & Monitoring methods?
A) In-situ metallography on selected surfaces and welds B) Hardness & tensile testing
C) Removal of full thickness samples for metallography D) Weld & HAZ tests using NDE
Answer: C … Ref: 4.2.1.7.a … Graphitization Insp & Monitoring

33
DM # 16 … TEMPER EMBRITTLEMENT  6 Q&A

16a. Temper embrittlement is reduction of toughness due to metallurgical change that can
occur in some low alloy steels as a result of long term exposure in this temperature range:
A) About 600°F to 1000°F (316 to 540°C) B) About 650°F to 1070°F (343 to 577°C)
C) About 800°F to 1100°F (427 to 593°C) D) About 850°F to 1400°F (440 to 760°C)
Answer = B … See Para 4.2.3.1 (Description of Dam)  Temper Embrittlement Range …

NOTE: A = 885°F Embrittlement, C = Graphitization, D = Spheroidization
16b. Equipment that is temper embrittled may be susceptible to this damage mechanism
during start-up and shut down:
A) Short term overheating/stress rupture B) Thermal Shock or Thermal Fatigue

C) Brittle Fracture D) Creep
Answer = C … See Paragraph 4.2.3.1 (Description of Damage)  Temper Embrittlement
16c. Which of the following steels are most susceptible to Temper Embrittlement?
A) Carbon steels B) C – 0.5 Moly C) 1.25Cr – 0.5 Mo D) 2.25Cr – 1Mo

Answer = D … See Paragraph 4.2.3.2.a below  Affected Materials
16d. Susceptibility to temper embrittlement is largely determined by the presence of which

of the following alloying elements?
A) Molybdenum, Chromium, & tramp elements (phosphorus, tin, antimony & arsenic)
B) Manganese, Chromium, & tramp elements (phosphorus, tin, antimony & arsenic)
C) Manganese, Silicon, & tramp elements (phosphorus, tin, antimony & arsenic)
D) None of the above is correct
Answer: C … Ref: 4.2.3.3.b  650°F to 1100°F (343°C to 593°C)… Critical Factors
16e. Temper embrittlement is not readily apparent, but can be confirmed through:
A) UT Shearwave backscatter technique B) Metallographic replication

C) Common RT techniques D) Impact testing
Answer: D … Ref: 4.2.3.5.a  650 to 1100°F (343 to 593°C) … Appearance & MOD
16f. If existing materials contain critical levels of the embrittling impurity elements and are
exposed in the embrittling range, temper embrittlement:
A) Can be prevented B) Cannot be prevented

C) Will be prevented D) None of the above are correct
Answer: B … Ref: 4.2.3.6.a.i  650 to 1100°F (343 to 593°C)… Prev/Mitigation

34
DM # 17 … DECARBURIZATION  5 Q&A
17a. A condition where steel loses strength due the removal of carbon and carbides leaving
only an iron matrix is called:
A) Decarburization
B) Spheroidization
C) Carburization
D) Graphitization
Answer = A … Ref: 4.4.4.1 … Decarburization  Description of Damage
17b. Decarburization may occur in equipment exposed to any of these conditions EXCEPT:
A) High temperature gas service B) Heat Treatment

C) Welding D) Fire
Answer = C … Ref: 4.4.4.1 … Decarburization  Description of Damage
17c. The extent and depth of decarburization is a function of:
A) Temperature and H2S partial Pressure

B) Temperature and Material properties
C) Temperature and Flow Velocity
D) Temperature and Exposure time
Answer: D … Ref: 4.4.4.3.c … Decarburization  Critical Factors
17d. Decarburization damage can be controlled/prevented by any of these below EXCEPT:
A) Control the chemistry of the gas phase and alloy selection per API RP 941
B) Use steels operating in high temperature hydrogen environments as per API RP 941
C) Perform PWHT of CS at elevated temps above 1200º F (649°C) to prevent decarburization
D) Use alloy steels with chromium & molybdenum to form more stable carbides & resist damage
Answer = C … See Para 4.4.4.6.a/b/c  Decarburization Prevention / Mitigation
17e. Suspected Decarburization is best verified using what inspection methods?
A) Metallography & VT
B) FMR & BHT
C) UT & MT
D) VT & RT
Answer = B … See Para 4.4.4.7.a/b … Decarburization  Inspection & Monitoring

35
DM # 18 … CAUSTIC (SCC) CRACKING  8 Q&A
18a. Another name for Caustic Stress Corrosion Cracking (SCC) is:
A) Alkaline SCC
B) Caustic Gouging
C) Ductile gouging
D) None of these
Answer = D … See Para. 4.5.3.1 … CAUSTIC SCC = CAUSTIC EMBRITTLEMENT
18b. Caustic embrittlement is a form of stress corrosion cracking characterized by Surface-

initiated cracks in piping and equipment exposed to caustic and located:
A) In the HAZ of welds always

B) Most often in the HAZ of welds
C) Mostly adjacent to Non-PWHT welds
D) Mostly adjacent to zones of high stress
Answer = C … See Para. 4.5.3.1 … CAUSTIC SCC  Description of Damage
18c. Susceptibility to Caustic SCC in caustic soda/caustic potash solutions is a function of:
A) Caustic strength, metal temp & stress levels

B) Metal temperature and stress levels
C) O2 content, caustic strength & stress levels
D) None of these
Answer = A … See Para. 4.5.3.3.a … CAUSTIC SCC  Critical Factors
18d. Regarding caustic embrittlement, which of these statements are true about caustic
concentrations and temperatures?
A) Decreasing concentrations & decreasing temps increases likelihood/severity of cracks

B) Decreasing concentrations & increasing temps increases likelihood/severity of cracks
C) Increasing concentrations & decreasing temps increases likelihood/severity of cracks
D) Increasing concentrations & increasing temps increases likelihood/severity of cracks
Answer = D … Ref: 4.5.3.3.b  Caustic Embrittlement = Caustic SCC … Crit Factors

36
DM # 18 … CAUSTIC (SCC) CRACKING  8 Q&A

18e. Caustic concentrations at what minimum ppm values can cause Caustic SCC?
A) 50-100 PPM
B) 100-150 PPM
C) 150-200 PPM
D) 200-250 PPM
Answer = A … Ref: 4.5.3.3.c  PWHT prevents Caustic SCC … Critical Factors
18f. Caustic embrittlement cracking can be effectively prevented by means of PWHT at a

temperature of:
A) 1100º F (593°C)
B) 1150º F (621°C)
C) 1200º F (649°C)
D) 1250º F (677°C)
Answer = B … Ref: 4.5.3.6.a  PWHT temps for Caustic SCC … Prev/Mit  NACE
SP0403 not requires a 1175 +25 F PWHT … So … C is correct in the field!!!
18g. How can Caustic Stress Corrosion Cracking be prevented on Non-PWHT’d CS lines?
A) Upgrade to 300 Series SS

B) Upgrade to the nickel alloy
C) Avoid steamout cleaning
D) None of these
Answer = C … See Para. 4.5.3.6.d … Caustic SCC  Prevention/Mitigation
18h. At higher temperatures and/or caustic concentrations, what material is more resistant
to Caustic embrittlement (Caustic SCC)?
A) Carbon steels that have received PWHT

B) Low alloy steels that have received PWHT
C) 300 Series Stainless steels
D) Nickel-based alloys
Answer = D … Reference: Caustic SCC  Par. 4.5.3.2, 4.5.3.3.b & Fig 4-146, & 4.5.3.6.c

37
DM # 19 … CAUSTIC CORROSION 9 Q&A

19a. Localized corrosion due to the concentration of caustic or alkaline salts that usually
occurs under evaporative or high heat transfer conditions is called:
A) Ammonium Chloride Corrosion

B) Alkaline Sour Water Corrosion
C) Caustic Corrosion
D) HCL Corrosion
Answer = C … See Para. 4.3.10.1 … Caustic Corrosion … Description of Damage
19b. Which statement is FALSE regarding Sources of Caustic Corrosion?
A) A concentrating mechanism is not required to build up caustic strength

B) Caustic may become concentrated by DNB, evaporation and deposition
C) Alkaline salts may enter process streams through leaks in condensers or process equipment
D) Process units use caustic solutions for neutralization & sulfur or chlorine compound removal
Answer = A … See Para. 4.3.10.3.a/b/c/d/e/f … Caustic Corrosion … Critical Factors
19c. Which is NOT a means for Caustic Corr to occur when caustic becomes concentrated?
A) DNB B) Evaporation
C) Deposition D) Precipitation
Answer = D … See Para. 4.3.10.3.f … Caustic Corrosion … Critical Factors
19d. Caustic corrosion is most often associated with all of these equipment types EXCEPT:
A) Boilers B) Steam Generating Equip

C) Heat Exchangers D) Crude Towers
Answer = D … See Para. 4.3.10.4.a … Caustic Corrosion … Affected Equipment
19e. Caustic Corrosion may appear as any of these EXCEPT:
A) General metal loss (In boiler tubes)

B) Grooving at top of tube (In horizontal tubes)
C) Localized metal loss (locally thinned under deposits)
D) Localized gouging along a waterline (circumferential grooves in vertical boiler tubes)
Answer = A … See Para. 4.3.10.5.a/b/c/d … Caustic Corr … Appearance  All = localized

38
DM # 19 … CAUSTIC CORROSION 9 Q&A

19f. Exposure to high solution strength caustic can result in:
A) General corrosion with very high corrosion rates above 175°F (79°C)
B) General corrosion with very high corrosion rates above 200°F (93°C)
C) General corrosion of CS above 175°F (79°C) & very high corrosion rates above 200°F (93°C)
Answer = B … See Para. 4.3.10.5.e … Caustic Corr … Appearance & Morphology
19g. Carbon steel and 300 Series SS have serious corrosion problems in high strength
caustic solutions above about:
A) 150°F (66°C)
B) 175°F (79°C)
C) 200°F (93°C)
D) 250°F (121°C)
Answer = A … See Para. 4.3.10.6.c … Caustic Corr … Prevention/Mitigation)
19h. Improved caustic corrosion resistance above 150°F (66°C) can be achieved by using:
A) Low Alloy Steels ≥ 7% Cr

B) Any grade of 300 Series Austenitic SS
C) Alloy 400 (Monel) & other nickel-based alloys
D) Only certain stabilized grades of the 300 Series SS
Answer = C … See Para. 4.3.10.6.c … Caustic Corr … Prevention/Mitigation)
19i. Which materials given below are the least susceptible to caustic corrosion?
A) Carbon Steel
B) Low Alloy steels
C) Certain grades of stabilized 300 Series SS
D) Nickel-based alloy
Answer = D … Ref: 4.3.10.2 & 4.3.10.6.c … … Caustic Corr … Affected Materials & P/M

39
DM # 20 … EROSION/EROSION – CORROSION
20a. Accelerated mechanical removal of surface material as a result of relative movement

between, or impact from solids, liquids, vapor or any combination thereof is known as:
A) Erosion B) Erosion-Corrosion
C) Corrosion D) None of these
Ans: A … API 571, Par. 4.2.14.1.a  Erosion/Erosion-Corrosion … Description of Damage
20b. Metal loss that is the result of impact or abrasion (often removing protective films and
scales) with contributing corrosion is called:
A) Pitting B) Erosion
C) Corrosion D) Erosion/Corrosion
Answer = D … See Para 4.2.14.1.a  Erosion/Erosion-Corrosion … Description of Damage
20b. In erosion/corrosion, Corrosion contributes to erosion by:
A) Causing general pitting only B) Causing localized pitting only

C) Causing abrasive wear D) Removing protective films & scales
Answer = D … See Para 4.2.14.1.a  Erosion/Erosion-Corrosion … Description of Damage
20c. Pure erosion is very rare and is sometimes referred to as:
A) Abrasive wear B) Undercutting

C) Tiger striping D) None of these
Answer: A … API 571, Para. 4.2.14.3.a – Erosion/Erosion-Corrosion … Critical Factors
20d. Crude and vacuum unit piping and vessels exposed to naphthenic acids in some crude
oils may suffer which type of damage and severe metal loss when the specific factors of
temperature, velocity, and sulfur content are considered?
A) Erosion B) Erosion-corrosion
C) Erosion and erosion-corrosion D) NAC and erosion and erosion-corrosion
Ans: B … API 571, Para. 4.2.14.4.d  Erosion/Erosion-Corrosion … Affected equipment

40
DM # 20 … EROSION/EROSION – CORROSION
20e. Erosion and Erosion-Corrosion are characterized by:
A) A localized loss in thickness due primarily to grooving
B) General uniform wall loss or localized loss in the form of pitting or grooving
C) A localized loss in thickness as pits, grooves, gullies, waves, rounded holes and valleys
D) General uniform wall loss or localized loss as pits, grooves, gullies, waves, and rounded holes
Answer: C … API 571, Para. 4.2.14.5.a  Erosion/Erosion-Corrosion … Appearance
20f. Improving design to prevent Erosion/Erosion-Corrosion does NOT involve:

A) Changes in shape (Increasing pipe diameter to decrease velocity)
B) Changes in geometry (Streamlining bends to reduce impingement)
C) Changes in material selection (To increase the remaining life of the equipment)
D) Changes in replacement practices (Eliminating the use of short-radius elbows when possible)
Answer: D … Ref: 4.2.14.6.a  Erosion/Erosion-corrosion  Prev by Design Improvement
20g. Improved resistance to erosion is achievable by any of these means except:

A) Increase substrate hardness using hard facing
B) Increase substrate composition using heat treatment
C) Increase substrate hardness using face-hardening treatments
D) Installation of those refractory systems that are Erosion resistant
Ans: B … Ref: 4.2.14.6.b  Increase hardness using harder alloys … Prev/Mitig
20h. Heat exchangers utilize which of these components to minimize erosion problems?
A) Impingement plates, tube ferrules, horizontal baffles and pass partition plates
B) Impingement plates, tube ferrules, and horizontal baffles only
C) Impingement plates and tube ferrules only
D) Impingement plates only
Answer: C … API 571, Par. 4.2.14.6.d – Erosion/Erosion-Corrosion … Affected equipment
20i. To detect extent of metal loss due to Erosion-Corrosion, what NDE methods are best?
A) Visual examination utilizing Internal Insp techniques inside piping followed by UT Thickness
B) Visual examination utilizing Internal Insp techniques inside piping on suspected areas
C) Visual examination of suspected or troublesome areas and UT checks or RT
D) UT checks or RT in suspected or troublesome areas
Answer: C … API 571, Par. 4.2.14.7.a – Erosion/Erosion-Corrosion … Insp & Monitoring

41
DM # 21 … CARBONATE SCC
21a. Which of the following SCC mechanisms may be found in an alkaline environment
and is also a form of Alkaline Stress Corrosion Cracking (ASCC)?
A) PASCC B) Carbonate SCC

C) Sour Water SCC D) Ammonia Bisulphate SCC
Answer = B … See Para 5.1.2.5.1 … Carbonate SCC  Description of Damage
21b. Carbonate SCC USUALLY OCCURS at welds or cold worked areas that:
A) Have been stressed relieved
B) Have not been stressed relieved
C) Have relatively low levels of residual stress
D) Have high residual stress or have high-applied stress
Answer = B … Reference: 5.1.2.5.3.b … Carbonate SCC  Critical Factors
21c. Carbonate SCC susceptibility:

A) Increases with increasing pH and increasing carbonate concentration
B) Increases with decreasing pH and increasing carbonate concentration
C) Increases with increasing pH and decreasing carbonate concentration
D) Increases with decreasing pH and decreasing carbonate concentration
Answer = A … Reference: 5.1.2.5.3.c … Carbonate SCC  Critical Factors
21d. Which statement is TRUE regarding the appearance of Carbonate SCC?

A) Typically propagates parallel to weld in HAZ or base metal within 1 in. (25 mm) of the weld
B) May be mistaken for SOHIC but cracking is further from weld toe (multiple parallel cracks)
C) It is sometimes described as craze cracks often initiated at weld-related flaws
D) Cracks can be similar in appearance to Chloride SCC
Answer = B … Reference: 5.1.2.5.5.a/b/c/d/e … Carbonate SCC  Appearance
21e. Which of these Prevention measures for Carbonate SCC are FALSE?
A) Application of PWHT to CS (1150°F or 621°C) is proven to prevent carbonate cracking
B) PWHT applies to repair of CS welds & any internal welds and also external attachment welds
C) Cracks can be eliminated by usage of effective barrier coatings or solid or clad 300 Series SS
D) Water wash non-PWHT’d piping/equip prior to steamout or PWHT in hot carbonate systems
Answer = A … See Para 5.1.2.5.6.a/bc … Carbonate SCC  Prev  PWHT 1200 - 1230°F
21f. Carbonate Stress Corrosion Cracking is best detected using what Inspection method?
A) VT B) PT C) WFMT D) DCFM
Answer = C … See Para 5.1.2.5.7.b … Carbonate SCC  Inspection & Monitoring

42
DM # 22 … AMINE CRACKING  6 Q&A

22a. In aqueous alkanolamine systems used to remove/absorb H²S and/or CO² and their
mixtures from various gas and liquid hydrocarbon streams, Amine SCC is a term applied
to the cracking of steels under the combined actions of:
A) Temperature and pressure B) Pressure and stress
C) Temperature and corrosion D) Tensile stress and corrosion
Answer: D … Ref: 5.1.2.2.1.a … Amine SCC  Description of Damage
22b. Which of these materials is not susceptible to amine cracking?

A) Carbon steels B) Low alloy steels
B) Both CS & LA Steels D) Both 300 & 400 Series SS
Answer: D … Ref: 5.1.2.2.1.c & 5.1.2.2.2 … Amine SCC  D of D & Affected Materials
22c. Amine cracking (form of Alkaline SCC) is more likely to occur in which services?
A) MDEA & ADIP B) ADIP & DIPA C) MEA & DEA D) DIPA & MEA
Answer = C … See Para. 5.1.2.2.3.c  Amine SCC … (Critical Factors)
22d. Regarding amine cracking (reported down to ambient temps with some amines),
which of the following statements are TRUE:
A) Decreasing temperatures & stress levels decreases the likelihood & severity of cracks
B) Decreasing temperatures & stress levels increases the likelihood & severity of cracks
C) Increasing temperatures & stress levels decreases the likelihood & severity of cracks
D) Increasing temperatures & stress levels increases the likelihood & severity of cracks
Answer: D … Ref: 5.1.2.2.3.d  … Amine SCC  Critical Factors  API style Q
22e. Amine stress corrosion cracking is most often associated with lean amine service and
pure alkanolamine does not cause cracking. Rich amine service cracking is most often
associated with which of the following?
A) H²S B) Wet H²S C) Stress D) Temperature

Answer: B … Reference: 5.1.2.2.3.e … … Amine SCC  Critical Factors
22f. Amine stress corrosion cracking can occur in non-PWHT’d piping & equipment when:
A) Exposed to steamout or short-term amine carryover

B) Exposed to wet H2S environment or CO2 carryover
C) Exposed to steamout or organic acid carryover
Answer: A … Reference: 5.1.2.2.3.f … Critical Factors
43
DM # 23 … CHLORIDE SCC
23a. Which of the following materials is susceptible to Chloride SCC?
A) Carbon steel B) 300 Series SS C) Low alloy steel D) 400 Series SS
Answer: B … Ref: 4.5.1.1 & 4.5.1.3.L … Chloride SCC  D of damage & Critical Factors
23b. Critical factors for Chloride SCC include all of the following EXCEPT:
A) Chloride content B) pH & temperature C) Alloy composition D) Stress & presence of CO²
Answer = D … Para. 4.5.1.3.a … Chloride SCC  Critical Factors  stress, O2 presence
23c. Regarding Chloride SCC, which of the statements below is TRUE?
A) Increasing temperatures & chloride levels increase susceptibility for cracking
B) Decreasing temperatures all but eliminates the susceptibility for cracking
C) Decreasing temperatures increases the susceptibility for cracking
Answer: A … Reference: 4.5.1.3.b/c … Chloride SCC  Critical Factors  API style Q
23d. Chloride SCC usually occurs above what metal temperature and pH value?
A) Above 125º F (52ºC) and pH 3.0 B) Above 140º F (60ºC) and pH 2.0
C) Above 175º F (79ºC) and pH 2.5 D) Above 200º F (93ºC) and pH 3.0
Answer: B … Ref: 4.5.1.3.g/f … Chloride SCC  Critical Factors
23e. Regarding Chloride SCC, which statements regarding nickel content are true?
A) Greatest susceptibility (≤ 3%), highly resistant (≥ 20%), nearly immune (≥ 30%)
B) Greatest susceptibility (3 – 8%), highly resistant (≥ 25%), nearly immune (≥ 35%)
C) Greatest susceptibility (8 – 12%), highly resistant (≥ 35%), nearly immune (≥ 45%)
D) Greatest susceptibility (12 – 20%), highly resistant (≥ 45%), no % immune from SCC
Ans: C … Ref: 4.5.1.3.j  Chloride SCC  usually above 140°F (60°C)… Critical Factors
NOTE: AFFECTED MATERIALS  Nickel based alloys are highly resistant to CLSCC
23f. Regarding the visual appearance (after PT) of Chloride SCC, which statement is true?
A) Parallel cracks in HAZ nearer to the fusion line
B) Parallel cracks in HAZ nearer to adjacent base metal
C) Spider web, branching and craze-cracked in appearance
Answer: C … Ref: 4.5.1.5.c & Fig 4-136  Chloride SCC  Appearance
23g. What are the preferred methods of detecting Chloride SCC?
A) PT only
B) PT or WFMPT
C) PT or Phase Analysis EC techniques
D) UT shearwave and RT, because PT cannot locate extremely fine cracks
Answer: C … Ref: 4.5.1.7.b  Chloride SCC  Inspection & Monitoring
44
DM # 24 … CARBURIZATION (9 Q&A)
24a. Which of these is NOT a condition for carburization to occur?
A) Temp high enough to allow diffusion of carbon into metal, usually above 1100°F (593°C)
B) Exposure to a carburizing environment or carbonaceous material
C) High oxygen potential
D) Susceptible material
Ans: C … Ref: 4.4.3.3.a.1/2/3  Carburization  Above 1100°F (593°C)… Critical Factors
24b. Conditions favoring carburization include a high gas phase carbon activity and:
A) Low oxygen potential

B) High oxygen potential
C) Positive oxygen potential
D) Negative oxygen potential
Answer: A … Ref: 4.4.3.3.c  Carburization Above 1100°F (593°C)… Critical Factors
24c. Carburization in carbon and low alloy steels occurs when carbon reacts to form:
A) A single phase microstructure where all of the pearlite has been removed
B) A single phase microstructure where all of the ferrite has been removed
C) A hard, brittle structure at surface that may crack or spall upon cooling
Answer: C … Ref: 4.4.3.3.d  Carburization Above 1100°F (593°C)… Critical Factors
24d. 300 Series SS are more resistant than CS & low alloy steels to Carburization due to:
A) The amount of ferrite that exists in the microstructure

B) The amount of martensite that exists in the microstructure
C) The higher chromium and nickel content in the microstructure
Answer: C … Ref: 4.4.3.3.e  Carburization Above 1100°F (593°C)… Critical Factors

45
DM # 24 … CARBURIZATION (9 Q&A)
24e. Carburization can result in any of the following deficiencies EXCEPT:
A) Loss of weldability
B) Loss of magnetism in some alloys
C) Loss of high temperature creep ductility
D) Loss of ambient temp mechanical properties (specifically toughness/ductility)
Answer: B … Ref: 4.4.3.3.f  Carburization  Loss of Corr Resistance … Critical Factors
24f. Most common equipment type susceptible to carburization in refining industry:
A) Reactors B) Heater Tubes

C) Heater exchangers D) Coke Drums
Answer: B … Ref: Par. 4.4.3.4.a …  Carburization … Affected Units or Equip
24g. Carburization can be confirmed by (Appearance & Morphology of Damage):
A) Substantial increases in hardness and loss of ductility

B) Substantial increases in hardness and loss of tensile strength
C) Substantial increases in hardness and loss of tensile strength and ductility
D) Slight increases in hardness and slight loss of tensile strength and ductility
Answer: A … Reference: 4.4.3.5.b   Carburization … Appearance & MOD
24h. Which of these is NOT an inspection & monitoring method for Carburization:
A) Inspection techniques based on determining increased levels of ferromagnetism are useful for
alloys that are paramagnetic when initially installed
B) If process side surfaces are accessible, hardness testing & field metallography can be used
C) Destructive sampling and magnetic based techniques (Eddy Current) have also been used
D) In early stages of carburization, RT, UT and some magnetic techniques may be used.
Answer: D … Reference: 4.4.3.7.a/b/c  Carburization … Insp & Monitoring … Answer D

is incorrect and these methods are only useful in advanced stages of carburization w/cracks
24i. A severe form of carburization (catastrophic carburization) is known as:
A) Decarburization B) Spheroidization
C) Metal Dusting D) Graphitization
Answer: C … Ref: Par. 4.4.3.8 …  Carburization related mechanism = Metal Dusting

46
DM # 25 … HYDROGEN EMBRITTLEMENT  10 Q&A

25a. Hydrogen Embrittlement (HE) can occur during manufacturing, welding, or:
A) Heat Treatment
B) From services that charge hydrogen into steel in aqueous, corrosive, or gaseous environments
C) Overpressurization during pressure testing
Answer = B … Para 4.5.6.1.1 … Hydrogen Embrittlement  Description of Damage
25b. A loss in ductility of high strength steels due to the penetration of atomic hydrogen
that can lead to brittle cracking is called:
A) Hydrogen Stress Cracking

B) Hydrogen Embrittlement
C) Temper Embrittlement
D) Brittle Fracture
Ans: B … Ref: 4.5.6.1.1  Correct = Hydrogen Embrittlement (Description of Damage)
25c. Hydrogen Embrittlement (HE) cannot occur if:
A) A stress above the threshold for HE must be present from residual and/or applied stresses
B) Strength level & microstructure of steel or alloy must be susceptible to embrittlement
C) HE occurs whenever metal temperatures are in the range above 300 °F (149°C)
D) Hydrogen must be present at a critical concentration within the steel or alloy
Ans: C … Ref: 4.5.6.3.a.1/2/3  Hydrogen Embrittlement = 3 conditions (Critical Factors)
25d. For Hydrogen Embrittlement, hydrogen can come from all these sources except:
A) Manufacturing processes such as Heat Treatment
B) Cleaning and pickling in acid solutions can account for hydrogen
C) Welding (wet electrodes can allow hydrogen to be charged into the steel = delayed cracking)
D) Services allow atomic hydrogen diffusion into steel (Wet H2S/HF acid/hi-temp hydrogen gas)
Ans: A … Ref: 4.5.6.3.b  HE Sources of hydrogen = melting practices (Critical Factors)
25e. Which statement regarding temperature is TRUE for Hydrogen embrittlement?
A) HE effects increase with increasing temperatures

B) HE never occurs above temps that are 180°F (82°C)
C) HE occurs at temperatures from ambient to about 300°F (149°C)
D) HE is not likely to occur above temperatures that are 160°F to 180°F (71°C to 82°C)
Ans: C … Ref: 4.5.6.3.c  Hydrogen Embrittlement (HE) = 3 conditions (Critical Factors)

47
DM # 25 … HYDROGEN EMBRITTLEMENT  10 Q&A

25f. Regarding Hydrogen Embrittlement, the amount of trapped hydrogen depends on the
environment, surface reactions and the presence of hydrogen traps in the metal such as:
A) Imperfections, inclusions and pre-existing flaws or cracks

B) Laminations and imperfections
C) Laminations & inclusions
Answer: A … Ref: 4.5.6.3.e  Hydrogen Embrittlement hydrogen traps (Critical Factors)
25g. Regarding HE, the amount of hydrogen needed to have a measurable effect on
mechanical properties for an alloy varies with:
A) Material strength level, microstructure & heat treatment

B) Microstructure and Young’s Modulus (i.e., Elasticity)
C) Microstructure & co-efficient of thermal conductivity
D) Material strength, microstructure and melting Point
Answer = A …Par. 4.5.6.3.f Hydrogen Embrittlement (Crit Factors)  4.5.6.4.a … PWHT
25h Which statement is NOT TRUE regarding appearance of Hydrogen Embrittlement?
A) Cracking due to HE can initiate sub-surface, but in most cases is surface breaking
B) HE occurs at locations of high residual or tri-axial stresses (notches, restraint)
C) HE occurs where the microstructure is conducive, such as in weld HAZ’s
D) In lower strength steels, cracking is often intergranular
Ans: D … Ref: 4.5.6.5.a/b/c/d Hydrogen Embrittlement  In higher strength … (App)
25i. Prevention/Mitigation measures for Hydrogen Embrittlement during welding include

all of the following precautions EXCEPT:
A) During welding, use low hydrogen electrodes

B) During welding, use dry electrodes and preheating methods
C) Elevated temperature bake out is done at temperatures of 300°F or higher (149°C or higher)
D) If hydrogen is expected to have diffused into metal, an elevated temp bake out may be needed
Ans: C … Ref: 4.5.6.6.c  HE Welding Precautions … 400°F (204°C) (Prev/Mitigation)
25j. Which Insp/Monitoring methods are best used to detect Hydrogen Embrittlement?
A) PT, MT or WFMT for surface cracks B) RT methods

C) Hydrogen flux monitoring using gas tester D) UT thickness checks
Answer: A … Ref: 4.5.6.7.a/b/c  UT (shear wave) may be useful (Insp & Monitoring)

48
DM # 26 … STEAM BLANKETING
26a. Steam blanketing is a condition that can cause eventual tube rupture due to Short
term overheating and discrete steam bubbles created form a blanket on ID surfaces called:
A) ANB B) DNA C) DEA D) DNB

Answer = D … See Para. 4.2.11.1 … Steam Blanketing  Description of Damage
26b. Steam blanketing is a condition that finally results in tube rupture due to:
A) Long term overheating B) Short term overheating

C) High temp corrosion D) Upgrade to nickel alloys
Answer = B … See Para. 4.2.11.1 … Steam Blanketing  Description of Damage
26c. Steam blanketing failures appear as:

A) Similar to Brittle Fracture without plastic deformation (exposed grains)
B) Open burst with fracture edges drawn to a near knife-edge appearance
C) Plastic deformation and fish mouth in appearance
Answer = B … See Para. 4.2.11.5.a … Steam Blanketing  Appearance
26d. Steam Blanketing is very similar to which API 571 Damage Mechanism listed below?
A) Short Term Overheating – Stress Rupture B) Creep and Stress Rupture

C) Thermal Fatigue D) Thermal Shock
Answer: A … API 571, Para. 4.2.11.8 – Steam Blanketing … Related Mechanisms
26e. Steam Blanketing critical factors include:
A) Material Creep resistance & O2 concentration B) Fluid velocity & equipment metallurgy
C) Heat flux and fluid flow D) None of these
Answer: C … API 571, Para. 4.2.11.3.a – Steam Blanketing … Critical factors
26f. Regarding Steam Blanketing, what is the best prevention method?
A) Assure proper material Creep resistance & limit O2 concentrations

B) Assure proper burner management to prevent flame impingement
C) Assure proper flow and minimize the starvation of heater tubes
D) None of these
Answer: B … Para. 4.2.11.6.a & 4.2.11.7 – Steam Blanketing … Prev & Insp & Mon
49
DM # 27 … THERMAL SHOCK
27a. This Damage Mechanism can occur when high and non-uniform thermal stresses
develop over a relatively short time in a piece of equipment due to differential expansion or
contraction, and if the thermal expansion/contraction is restrained, stresses above the
material’s yield strength can result:
A) Thermal Fatigue B) Thermal Shock C) Thermal Stress D) Stress Rupture
Answer: B … Reference: 4.2.13.1  Thermal Shock (Description of Damage)
27b. Critical Factors related to Thermal Shock include all of the following EXCEPT:
A) Fracture is related to constraint on a component that prevents the component from expanding
or contracting with a change in temperature
B) Magnitude of the temperature differential & the material coefficient of thermal expansion
determine the magnitude of the stress
C) Thermal stresses generated by temperature cycling of the material may initiate fatigue cracks
D) Temperature changes that can result from water quenching as a result of rain deluges
Answer: C … Reference: 4.2.13.3.a  Thermal Shock … Cyclic stresses (Critical Factors)
27c. Which of the following define the appearance and morphology of Thermal Shock?
A) Cracks propagate transverse to stress & are usually dagger-shaped/Transgranular/oxide filled
B) Surface initiating cracks, wide & often filled with oxides due to elevated temp exposure
C) Cracking may be axial or circumferential, or both, at the same location
D) Surface initiating cracks that may also appear as craze cracks
Ans: D … Ref: 4.2.13.5  Thermal Shock (Appearance & Morph) A/B/C = Thermal Fatigue
27d. Which of these are NOT TRUE regarding Prevention / Mitigation measures to be
taken for Thermal Shock?
A) Install thermal sleeves to allow proper heat transfer on to the pressure boundary component
B) Prevent interruptions in high temp line flow & minimize rain or fire water deluge situations
C) Review hot/cold injection points for potential thermal shock
D) Design to minimize severe restraint
Ans: A … Ref: 4.2.13.6.a/b/c/d/e  Thermal Shock (Prev./Mitig.)Prevent liquid impingement
27e. Regarding Thermal shock, which statement is true regarding Insp & Monitoring?
A) TS is highly localized and difficult to locate and PT and MT can be used to confirm cracking
B) TS occurs in stages and MT & PT are very effective in identifying the onset of the damage
C) TS is easily located and PT and MT can be used to confirm cracking
D) TS is always surface connected and can be easily found visually
Answer: A … Reference: 4.2.13.7.a/b  Thermal Shock (Inspection & Monitoring)

50
DM # 28 … CAVITATION … 9 Q&A
28a. Cavitation is a form of erosion caused by:
A) Formation of innumerable tiny vapor bubbles that expand to cause impact damage
B) Formation of innumerable tiny vapor bubbles that collapse instantly causing damage
C) Formation of innumerable tiny vapor bubbles that cover the affected area causing damage
D) Formation of innumerable tiny vapor bubbles with entrained corrosive gases causing damage
Answer = B … See Para. 4.2.15.1.a/b …  Cavitation (Description of Damage)
28b. A form of erosion caused by the formation and instantaneous collapse of innumerable
tiny vapor bubbles is called:
A) Condensate corrosion B) Cavitation

C) Steam blanketing D) None of these are correct
Answer: B … Ref: 4.2.15.1  Cavitation … Description of damage
28c. Cavitation is most commonly found in piping at areas:
A) Immediately downstream of orifice plates or control valves

B) Immediately downstream of pump discharge locations
C) Just upstream of orifice plates or control valves
D) Immediately upstream of pump discharge locations
Answer = A … See Para. 4.2.15.4 (Affected Units or Equipment)
28d. Cavitation is best prevented by changing the material properties or by avoiding those
conditions that would allow the:
A) Absolute pressure to fall below the vapor pressure of the liquid

B) Maximum pressure of the liquid to rise above the NPSH available (NPSHA)
C) Minimum pressure of the liquid to drop below the NPSH available (NPSHA)
D) None of these are correct because bypass lines must be used to control NPSHA
Answer: A … Reference: 4.2.15.3.a & 4.2.15.6.a … CF & Prevention/Mitigation
28e. Cavitation damage generally looks like:
A) Sharp-edged pitting but may also exhibit a gouged appearance in rotating components
B) Rounded edged pitting (similar to MIC) in all affected equipment
C) Deep grooving and often holing through components
Answer: A … Ref: 4.2.15.5.a  Cavitation  appearance

51
DM # 28 … CAVITATION … 9 Q&A
28f. Which of these is NOT a measure to take to prevent Cavitation?
A) Streamline flow path (reduce turbulence)/decrease fluid velocity/remove entrained air

B) Decrease the suction pressure of pumps/alter fluid properties by adding additives
C) Use of harder and/or more corrosion resistant alloys
D) Use hard surfacing or hard facing
Answer: B … Ref: 4.2.15.6.b  Cavitation  Increase suction pressure  Prevention
28g. Cavitating pumps may sound like:
A) Grinding metal noise coming from equipment

B) Whining high-pitched noise coming from equipment
C) Pebbles are being thrashed around inside the equipment
D) None of these as cavitation is vibrational (requires acoustic monitoring)
Answer: C … Ref: 4.2.15.7.a  Cavitation  Inspection and Monitoring
28h. Which is these is an API 571 recognized method of monitoring Cavitation?
A) Monitoring fluid behavior

B) Monitoring the acoustics of turbulent areas to detect characteristic sound frequencies
C) Using a stethoscope to listen for cavitation inside rotating equipment (Impeller vanes)
D) None of these as cavitation requires detailed vibrational analysis and sophisticated equipment
Answer: B … Ref: 4.2.15.7.b  Cavitation  Inspection and Monitoring
28i. Cavitation damage may be assessed by all of these NDE methods EXCEPT:
A) ET B) Acoustic Monitoring C) UT & RT D) VT
Answer: A … Ref: 4.2.15.7.c  Cavitation  Inspection and Monitoring
28j. The minimum head required to prevent Cavitation with a given liquid at a given flow
rate is called:
A) Net Positive Suction Head (NPSH)

B) Net Positive Suction Head Available (NPSHA)
C) Net Positive Suction Head Required (NPSHR)
Answer: C … Reference: 4.2.15.3.a … CF  NPSH(R)

52
DM # 29 … GRAPHITIC CORROSION  5 Q&A

29a. Regarding graphitic corrosion, Cast irons are comprised of graphite particles
embedded in an iron matrix that becomes deteriorated resulting in:
A) Graphite Dust B) Porous Graphite

C) Graphite Nodules D) Graphite Needles
Answer: B … Ref: 4.3.12.a  Graphitization  Description of Damage
29b. Graphitic corrosion usually occurs under all of these conditions EXCEPT:
A) Where low pH exists

B) Where stagnant conditions exist
C) Where soil is in contact with equipment
D) Where waters are very high in acids and oxygen
Answer: D … Ref: 4.3.12.b  Graphitization  Description of Damage  High sulfates
29c. Materials most susceptible to graphitic corrosion are:
A) Carbon Steels
B) Wrought Irons
C) Gray Cast Irons
D) White Cast Irons
Answer = C … See Para. 4.3.12.2 … Graphitic Corrosion  Affected Materials
29d. Which statement is FALSE regarding the appearance of graphitic corrosion?
A) Damage may be widespread or in localized areas with the majority of a component unaffected
B) Damage may not be noticed on visual inspection even where full wall thickness is degraded
C) Metallographic examination may be required to confirm extent of damage
D) Damaged areas will be hardened and discolored usually charcoal gray
Answer = D … See Para. 4.3.12.5.a/b/c/d … Graphitic Corrosion  Appearance  Soft &

easily gouged by hand tools
29e. Graphitic corrosion is also known as:
A) Hi-Temp Hydrogen attack and is a form of hi-temperature damage

B) Ductile Gouging and is a Metallurgical Change
C) Selective Leaching and is a form of Dealloying
Answer = C … See Para. 4.3.12.8 … Graphitic Corrosion  Related Mechanisms

53
DM # 30 – Short-term Overheating / Stress Rupture

30a. Permanent deformation occurring at relatively low stress levels as a result of localized
overheating (usually flame impingement) that results in bulging and eventually failure by:
A) Stress rupture B) Thermal Shock

C) Brittle Fracture D) Temper embrittlement
Answer: A …Ref: 4.2.10.1  Short term overheating – Stress rupture (Descrip of Dam)
30b. Regarding Short Term Overheating – Stress Rupture, which of the following
equipment items is NOT susceptible?
A) All Boiler & Fired Heater Tubes

B) Hydroprocessing Reactors (reactor beds)
C) Refractory Lined Equipment in FCC and Sulfur Plants
D) Mix points in hot streams (de-superheating, attemporating equipment)
Answer: D … API 571, Par. 4.2.10.4  D = Thermal Fatigue item … Affected equipment
30c. Elevated temp failure by localized overheating resulting in bulging (3-10%) &
thinning & eventual stress rupture by open “fish mouth” failures is known as:
A) Creep B) Thermal Shock

C) Oxidation D) Short term Overheating
Ans = D … See Par 4.2.10  Short term overheating – Stress rupture (Descript of Damage)
30d. Appearance (or morphology) of Short Term Overheating – Stress Rupture damage
can include all of the following except:
A) Localized deformation or bulging having a diameter increase of 3% to 10% or more

B) Ruptures that show thinning at the fracture surface
C) Ruptures that have a “fish mouth” appearance
D) Cracks propagate transverse to the stress
Ans: D … API 571, Para. 4.2.10.5  D = Thermal Fatigue … Appearance or Morphology
30e. Stress rupture failures are characterized by what appearance and morphology?
A) Open fish-mouth failures accompanied by bulging and thinning at fracture surfaces

B) Knife-edge failures that are accompanied by bulging and thinning at fracture surfaces
C) Rapid grainy failures usually accompanied by wide cracks and clean fracture surfaces
D) Dagger-shaped failures accompanied by wide cracks and oxide filled fracture surfaces
Ans: A … Ref: 4.2.10.5.b … App & MOD … Critical Note is that bulging is usually in the
area of 3 – 10% of nominal OD … D = Thermal Fatigue, B = steam blanketing
54
DM # 31 … BRITTLE FRACTURE
31a. The sudden rapid fracture under stress (residual or applied) where the material
exhibits little or no evidence of ductility or plastic deformation is called:
A) Thermal fatigue B) Thermal shock

C) Brittle fracture D) Temper Embrittlement
Answer: C … Ref: 4.2.7.1  Brittle Fracture … Description of Damage
31b. Which of these materials are NOT susceptible to brittle fracture?
A) Carbon steels B) Low Alloy steels

C) 400 Series SS D) 300 Series SS
Answer: D … Ref: 4.2.7.2 … Affected Materials
31c1. Select the item below that is a critical factor for brittle fracture:
A) Material fracture toughness as measured in a Charpy impact test

B) Material tensile strength as measured in a tensile test
C) Material elasticity as measured in a guided bend test
D) Material hardness as measured by Brinnell method
Answer: A … API 571 … Para. 4.2.7.3 … Brittle Fracture … Critical Factors
31c2. Regarding brittle fracture, when the critical combination of three factors is reached,
brittle fracture can occur. Select the item that is NOT a critical factor for brittle fracture:
A) Material fracture toughness (resistance to crack like flaws) as measured in Charpy impact test
B) Material tensile strength (resistance to crack like flaws) as measured in a tensile test
C) Size, shape and stress concentration effect of a flaw
D) Amount of residual and applied stresses on the flaw
Answer: B … API 571 … Para. 4.2.7.3 … Brittle Fracture … Critical Factors
31d. Most cases of Brittle Fracture occur only at:
A) Temperatures above Charpy Impact transition temperatures

B) Charpy Impact temperatures have no relationship to Brittle Fracture occurrences
C) Temperatures below ambient and only in thick sections
D) Temperatures below Charpy Impact transition temperatures
Answer = D … See Paragraph 4.2.7.3.e below  Critical Factors

55
DM # 31 … BRITTLE FRACTURE
31e. Main concern during start-up, shutdown and/or hydrotesting for equip/piping
operating at elevated temps and this event can also occur in an auto refrigeration event in
units processing light hydrocarbons:
A) Stress fracture B) Carburization

C) Spheroidization D) Brittle fracture
Answer: D … Ref: 4.2.7.4.c/d  Brittle Fracture … Affected Units or Equipment
31f. Cracks that are typically straight, non-branching, and devoid of any associated plastic
deformation are likely associated with which type of failure?
A) Chloride SCC B) Brittle fracture

C) Thermal fatigue D) Stress Rupture
Ans: B … Ref: 4.2.7.5.a & Fig 4-6 & 4-7  Brittle Fracture … Appearance or MOD
31g. Regarding brittle fracture failures, cracking found by the Inspector will typically show
evidence of:
A) Straight, non-branching cracks largely without evidence of any associated plastic deformation
B) Branching cracks having evidence of a shear lip or localized necking around the cracks
C) Both straight & multi-facet cracks with evidence of a shear lip or localized necking at cracks
Answer: A … API 571 … Para. 4.2.7.5.a … Brittle Fracture … Appearance or morphology
31h. Some reduction in the likelihood of a Brittle Fracture may be accomplished by

performing all of the following except:
A) Performing PWHT on a weld repaired/modified vessel in service when PWHT was not done
B) Performing PWHT on a vessel if it was not originally done during manufacturing
C) Perform a “warm” pre-stress hydrotest followed by a lower temperature hydrotest
D) Periodic inspections are to be performed at high stress locations
Answer = D … See Paragraph 4.2.7.6.d  Prevention/Mitigation

56
DM # 32 … SIGMA PHASE EMBRITTLEMENT (6 Q&A)

32a. Formation of a metallurgical phase known as sigma phase can result in:
A) A loss of fracture toughness in some stainless steels as a result of high temperature exposure
B) A loss of tensile strength in some stainless steels as a result of high temperature exposure
C) A loss of creep ductility in some stainless steels as a result of high temperature exposure
Answer: A … Ref: 4.2.6.1 … Sigma Phase  Description of Damage
32b. Cast 300 Series SS including the HK and HP alloys are especially susceptible to sigma
formation because of:
A) High Ferrite Content (10% - 40%) B) Low Ferrite Content (Up to 10%)
C) Excessive operating temperatures D) None of these are correct
Answer: A … Ref: 4.2.6.2.a … Sigma Phase  Affected Materials
32c. Sigma phase embrittlement affects all these Materials EXCEPT:

A) Austenitic & Super Austenitic SS B) Ferritic & Martensitic SS
C) Nickel-based alloys D) Duplex SS
Answer = C … See Para 4.2.6.2.a/b/c … Sigma Phase  Affected Materials
32d. Sigma phase embrittlement occurs when materials are exposed to operating temps of:
A) 650°F to 1070°F (343 to 577°C) B) 800°F to 1100°F (427 to 593°C)
C) 850°F to 1400°F (440 to 760°C) D) 1000°F to 1700°F (538°C to 927°C)
Answer = D … See Paragraph 4.2.6.3.c  Critical Factors
32e. Damage from sigma phase in the area of welds and high restraint areas appears in a
variety of stainless steels in the form of:
A) Corrosion B) Hardness C) Cracking D) Loss of Ductility
Answer: C … Ref: 4.2.6.5.b … Apppearance & Morphology of Damage
32f. Stainless steel cyclones, piping ductwork and valves in high temperature FCC
regeneration service are susceptible areas for (which of these DMs)?
A) Brittle fracture B) Sigma phase
C) Cavitation D) Corrosion fatigue
Answer: B … Ref: 4.2.6.4.a  Sigma Phase … Affected Units or Equipment

57
DM # 33 … 885°F (475°C) Embrittlement (10 Q&A)

33a. 885°F (475°C) Embrittlement can occur in this temperature range:
A) 700 – 1000°F (370 – 538°C)

B) Above 1000°F (538°C)
C) 450 – 600°F (232 – 315°C)
D) 600 – 1000°F (315 – 538°C)
Answer = D … See Paragraph 4.2.5.1  Description of Damage
33b. A loss in toughness due to a metallurgical change that can occur in alloys having a
ferrite phase, resulting from exposure in temp range 600 to1000º F (316 to540º C):
A) Caustic embrittlement B) Sigma Phase

C) 885º F embrittlement D) Temper embrittlement
Answer: C … Ref: 4.2.5.1 … Description of Damage
33c. Which of the following materials is least affected by 885º F Embrittlement?
A) Wrought & cast 300 Series SS containing ferrite, including welds and weld overlays
B) Low ferrite alloys (some austenitic stainless steels) or non-ferritic alloys
C) 400 Series SS (such as 405, 409, 410, 410S, 430, and 446)
D) Duplex SS (such as Alloys 2205, 2304, and 2507)
Answer: B … Ref: 4.2.5.2 &4.2.5.6.a (1st Edit, Pg 4-14) … Affected Materials & P/M
33d. Which of these materials is NOT susceptible to 885º F embrittlement?
A) Low ferrite or non-ferritic alloys

B) Duplex SS (Alloys 2205, 2304, 2507)
C) 400 Series SS (405, 409, 410, 410S, 430, 446)
D) Wrought & cast 300 Series SS containing ferrite (welds, weld overlays)
Answer: A … Ref: 4.2.5.2 & 4.2.5.6 … Affected Materials & P/M
33e. The best way to prevent 885ºF embrittlement is to avoid exposing susceptible materials
to the embrittling range or use:
A) Any Austenitic SS alloys

B) Any Martensitic SS alloys
C) Low-ferrite or non-ferritic alloys
D) Any of the high chromium alloys
Answer: C … Reference: 4.3.5.3.a & 4.2.5.6.a … Critical factors & Prev/Mitigation

58
DM # 33 … 885°F (475°C) Embrittlement (8 Q&A)

33f. Because of this damage mechanism, Ferritic SS alloys are usually not used in pressure
boundary applications and are limited to structural applications only:
A) Creep B) HTHA
C) 885°F Embrittlement D) None of these
Answer: C … Ref: 4.2.5.4.b … 885°F Embrittlement Affected Units or Equip
33g. A common example of a failure due to 885°F Embrittlement occurs when:
A) Attempting to weld dissimilar materials that have operated from 600 – 1000°F (316 – 540°C)
B) Attempting to weld dissimilar materials that have been operating above 885°F (475°C)
C) Attempting to weld or straighten bent, upset tower trays of Type 409 and 410 material
D) None of these
Answer: C … Ref: 4.2.5.4.c … 885°F Emb  Aff Equip  Never straighten bent trays
33h. 885°F Embrittlement is a metallurgical change that is:
A) Readily apparent with Metallography and can be confirmed also by bend or impact testing
B) Not readily apparent with Metallography but can be confirmed by bend or impact testing
C) Readily apparent with Metallography and can be confirmed also by impact testing only
D) Not readily apparent with Metallography but can be confirmed by bend testing only
Answer: B … Ref: 4.2.5.7.a … Appearance  Never straighten/weld bent trays
33i. 885°F Embrittlement is a metallurgical change this is:
A) Readily apparent with Metallography and can be confirmed also by hardness testing
B) Not readily apparent with Metallography and can be confirmed by hardness testing
C) Readily apparent with Metallography and can also be confirmed by impact testing
D) Not readily apparent with Metallography and cannot be confirmed by any test
Answer: B … Ref: 4.2.5.5.a & 4.2.5.5.7.c … 885°F Embritt  Appear & Insp & Monitor
33j. The existence of 885°F Embrittlement can be identified by:
A) Bend or impact testing

B) An increase in hardness in affected areas
C) A decrease in notch-toughness at affected welds
D) None of these methods identify the damage (found only by metallography)
Answer: B … Ref: 4.2.5.5.a … 885°F Embrittlement  An increase in hardness!!!

59
DM # 34 … SPHEROIDIZATION
34a. Spheroidization or Softening occurs above what minimum temperature and is usually
accompanied by loss of strength, creep resistance and:
A) 850°F (454°C), with ductility increase and deformation at stress concentrations

B) 850°F (454°C), with ductility decrease and deformation at stress concentrations
C) 1025°F (552°C), with ductility increase and reduction of stress concentrations
D) 1300°F (704°C), with ductility decrease and yielding at stress concentrations
Ans: A … Ref: 4.2.2.1/ 5.1.2.2.3.e  850°F - 1400°F (440-760C) … DOD & AU or E
34b. Spheroidization and graphitization are competing mechanisms that occur at

overlapping temperature ranges. Spheroidization tends to occur preferentially above this
temperature while graphitization predominates below this temperature:
A) 1000º F (538°C)
B) 1025º F (552°C)
C) 1050º F (565°C)
D) 1100º F (593°C)
Answer: B … Ref: 4.2.2.8.b  Competing DMs … Related Mechanisms
34c. A change in steel microstructure after exposure in 850°F to 1400°F (440°C – 760°C)
range, where the carbide phases in CS are unstable and may change from their normal
plate-like form to a spheroidal form, causing a loss in strength and/or creep resistance is:
A) Graphitization B) Spheroidization
C) Creep D) Oxidation
Answer: B … API 571 … Para. 4.2.2.1 … Spheroidization … description of damage
34d. Which of these may indicate a spheroidized microstructure?
A) A reduction in tensile strength and hardness

B) A reduction in low creep ductility
C) A reduction in fracture toughness
Answer: A … 571, Par. 4.2.2.1/4.2.2.7 … Spheroidization … DOD/Inspection & Monitoring

60
DM # 35 … REHEAT CRACKING
35a. PWHT relaxation cracks are also known as:
A) Reheat Cracks B) Stress Cracks C) Stress Corrosion Cracks D) None of these
Ans = A … See Para. 4.2.19.1 (DOD) … PWHT relaxation cracks = called Reheat cracking
35b. Reheat cracking due to PWHT or elevated temp service occurs above what temp?
A) 750º F (399°C)
B) 1025º F (552°C)
C) 1050º F (565°C)
D) 1100º F (593°C)
Ans = A … See Para. 4.2.19.1 (DOD) … PWHT relaxation cracks = called Reheat cracking
35c. Regarding susceptibility to reheat cracking, which of these statements are true?
A) Large grain size = more ductile HAZs, making a material more susceptible to cracking
B) Small grain size = more ductile HAZs, making a material more susceptible to cracking
C) Small grain size = less ductile HAZs, making a material more susceptible to cracking
D) Large grain size = less ductile HAZs, making a material more susceptible to cracking
Answer: D … Ref: 4.2.19.3 & 4.2.19.6.b … Reheat Cracking … CF & Prev/Mitigation
35d. Regarding prevention/mitigation of reheat cracking, which of the following statements

is NOT TRUE?
A) Short radius fillets or undercut can give rise to stress concentrations

B) In design and fabrication, it is advisable to avoid sharp changes in cross section
C) Circumferential welds are particularly susceptible due to mismatch & fit up problems
D) Metallurgical notches from the welding operations are often a cause of HAZ cracking
Answer: C … Ref: 4.2.15.3.a & 4.2.15.6.a … Reheat Cracking … CF & Prev/Mitigation
35e. Reheat Cracking may also be referred to in literature (is also known) as:
A) Both Stress Relief Cracking and Stress Relaxation Cracking

B) Both Stress Relief Cracking and Stress Corrosion Cracking
C) Stress Relaxation Cracking and Stress Corrosion Cracking
D) Stress Relief Cracking only
Answer = A … See Para. 4.2.19.8 … Reheat Cracking … Related Mechanisms

61
DM # 36 … SULFURIC ACID CORROSION (5 Q&A)
36a. Sulfuric Acid Corrosion is the most severe at what locations in Carbon Steel (tanks)?
A) At the Liquid line B) At the tank bottom (BS&W layer corrosion)

C) At the weld HAZ’s D) Anywhere in the pressure boundary
Answer = C … See Para 5.1.1.11.1 … Sulfuric Acid Corrosion  Description of Damage
36b. Regarding Sulfuric acid corrosion, which of these includes all critical factors?
A) Acid concentration, temperature, and velocity

B) Acid concentration, alloy content, and velocity
C) Acid concentration, temperature, alloy content, velocity & presence of oxidizers
D) Acid concentration, temperature, alloy content, velocity & presence of contaminants
Answer: C … Ref: 5.1.1.11.3.a … Sulfuric Acid Corrosion … Critical Factors
36c. Sulfuric acid corrosion rates increase significantly in CS below what % of acid
concentration?
A) 65% B) 75% C) 85% D) 97%
Answer: A … Ref: 5.1.1.11.3.c … Sulfuric Acid Corrosion … Critical Factors
36d. Per API 571, Sulfuric acid corrosion rates increase significantly in CS if flow velocity:
A) Exceeds 1 to 2 feet per second (0.3 to 0.6 meters/second)

B) Exceeds 2 to 3 feet per second (0.6 to 0.9 meters/second)
C) Exceeds 2 feet per second (0.6 meters/second)
Answer: B … Ref: 5.1.1.11.3.c … Sulfuric Acid Corrosion … Critical Factors
36e. Sulfuric acid corrosion on economizers or other carbon steel or low alloy steel
components will have (appearance or morphology of damage):
A) General wastage often with broad shallow pits, depending on how the sulfuric acid condenses
B) Linear type pitting at the high point in the system
C) General mild pitting throughout the system
Answer: A … API 571, Par. 4.3.7.5.a  TRICK QUESTION … Flue-Gas Dew Point Corr
… Appearance or MOD

62
DM # 37 … HYDROFLUORIC (HF) ACID CORR (9 Q&A)

37a. Hydrofluoric acid corrosion can result in high rates of general or localized corrosion
and may be accompanied by:
A) Hydrogen cracking, blistering and/or HIC/SOHIC

B) HCL acids
B) HTHA
Answer: A … Reference: 5.1.1.6.1  HF Acid Corrosion  Description of Damage
37b. Regarding Hydrofluoric acid corrosion, what materials are generally not suitable for
HF service (Susceptible to cracking and corrosion)?
A) Low Alloy Steels and 300 and 400 Series SS

B) Low Alloy Steels and 400 Series SS
C) 300 Series SS & 400 series SS
D) Carbon and Low Alloy Steels
Answer: A … Reference: 5.1.1.6.1  HF Acid Corrosion  Description of Damage
37c. Regarding hydrofluoric acid corrosion, corrosion rates:
A) Increase with increasing temps and decreasing HF concentration (& increasing H²O)
B) Increase with decreasing temps and decreasing HF concentration (& increasing H²O)
C) Decrease with increasing temps and decreasing HF concentration (& increasing H²O)
D) Decrease with decreasing temps and decreasing HF concentration (& increasing H²O)
Answer: A … Reference: 5.1.1.6.3.f  1-3% H²O in the HF acid … Critical Factors
37d. Typical HF Alkylation units prevent HF Acid corrosion by operating with:
A) 10% to 30% water in the acid and at temps generally below 250°F (121°C)
B) 1% to 3% water in the acid and at temps generally below 250°F (121°C)
C) 1% to 3% water in the acid and at temps generally below 150°F (66°C)
D) 65% HF acid and at temps generally below 300°F (149°C)
Answer: C … Reference: 5.1.1.6.3.e  CF  1-3% H²O in HF acid & 150°F (66°C Rule)
37e. In hydrofluoric acid service, residual elements (RE) consisting of %Cu, %Ni, %Cr used in
CS are best limited to:
A) 0.10% maximum B) 0.15% maximum

C) 0.30% maximum D) 0.50% maximum
Answer: B … Ref: 5.1.1.6.3.e/f  1-3% H²O in the HF acid … Critical Factors

63
DM # 37 … HYDROFLUORIC (HF) ACID CORR (9 Q&A)

37f. When oxygen is present in a moist HF Acid Vapor stream, which of these will reduce
the susceptibility of stress corrosion cracking (SCC) for Alloy 400 (Monel)?
A) Water wash B) Steamout C) PWHT D) None of these
Ans: C … Ref: 5.1.1.6.3.i & 5.1.1.6.6d  HF Acid Corr  CF & Prevention
37g. Preferential corrosion in HF Acid Service is covered in which of these documents?
A) API 751 guidelines for Residual elements (RE)

B) API 945 guidelines and Curves
C) General corrosion
D) None of these
Ans: A … Ref: 5.1.1.6.5.a & API RP 751  HF Acid Corr  Appearance
37h. HF Acid Corrosion in Carbon Steel may be accompanied by:
A) Preferential corrosion of both the base metal and weld metal

B) Hydrogen stress cracking, blistering and / or HIC SOHIC damage
C) General uniform corrosion or localized corrosion as outlined in API 751 Guidelines
D) Significant fouling due to iron sulfide scales and the presence of accelerated Oxygen
Ans: B … Ref: 5.1.1.6.5.b/c  HF Acid Corr  Appearance
37i. Inspection and monitoring for HF Acid Corrosion in CS does NOT require:
A) UT and RT to monitor loss in thickness

B) Special monitoring program for small bore piping and flange face corrosion
C) Special monitoring program for blistering and HIC/SOHIC as recommended in API 751
D) Tracking & Monitoring RE content of CS components in accordance with API 945 guidelines
Ans: D … Ref: 5.1.1.6.5.b/c  HF Acid Corr  Insp & Monitoring  API 751 for RE

64
DM # 38 … FLUE GAS DEW POINT CORR

38a. When Sulfur & chlorine species in fuel will form sulfur dioxide, sulfur trioxide &
hydrogen chloride within the combustion products, and low enough temperatures exist,
then gases & water vapor in the flue gas will “condense” to form sulfurous acid, sulfuric
acid & hydrochloric acid which can lead to this type of severe corrosion which is known as:
A) CO2 Corrosion B) Flue-Gas Dew Point Corrosion
C) Cooling Water Corrosion D) None of these are correct
Answer: B … API 571, Para. 4.3.7.1  Flue-Gas Dew Point Corr … Description of Damage
38b. Which of these statements regarding Flue-gas dew point corrosion are false?
A) Sulfur & chloride concentrations in the fuel and operating temps are critical factors
B) Sulfuric and sulfurous acid corrosion occurs if metal temps fall below the dew point
C) HCl dew point (130°F/54°C) depends on hydrogen chloride concentrations in the gas
D) Sulfuric acid dew point (140°F/60°C) depends on sulfur trioxide concentration in gas
Answer: D … Reference: 4.3.7.3.a/b/c/d … (280°F/138°C) … Critical factors
38c. Dew point corrosion (flue gas) can occur if the metal temperature is below the dew
point. The dew point of sulfuric acid is typically about:
A) 130º F (54ºC) B) 220º F (104ºC) C) 280º F (138ºC) D) 310º F (154ºC)
Answer: C … Ref: 4.3.7.3.c  Dew point Hydrochloric acid = A … Critical Factors
38d. The Dew Point of HCl (hydrochloric acid) in flue gas is typically:
A) 280°F (138°C) B) 130°F (54°C) C) 350°F (177°C) D) At Ambient temperature
Answer = B … See Paragraph 4.3.7.3.c/d  Critical Factors

38e. Sulfuric acid corrosion on economizers or other carbon steel or low alloy steel
components will have (appearance or morphology of damage):
A) General wastage often with broad shallow pits, depending on how the sulfuric acid condenses
B) Linear type pitting at the high point in the system
C) General mild pitting throughout the system
Answer: A … API 571, Par. 4.3.7.5.a  Flue-Gas Dew Point Corr … Appearance or MOD
38f. For 300 Series SS feed water heaters in HRSG’s, SCC will appear as:
A) Surface breaking cracks with a general crazed appearance (network of branching cracks)
B) Shallow surface breaking cracks generally straight and tight
C) Surface breaking cracks generally straight and open
D) Surface breaking cracks, spider web appearance
Answer: A … API 571, Para. 4.3.7.5.b – Flue-Gas Dew Point Corrosion Question
65
DM # 39 … DISSIMILAR METAL WELD (DMW) CORR

39a. Which of these statements is TRUE regarding dissimilar metal weld (DMW) cracking
when austenitic to ferritic welds operate at high temperatures?
A) It occurs on austenitic side of weld in the base metal outside of the HAZ
B) It occurs on ferritic side of weld in the base metal outside of the HAZ
C) It occurs on austenitic side of weld along the weld toe at the HAZ
D) It occurs on ferritic side of weld along the weld toe at the HAZ
Answer: D … Ref: 4.2.12.1 & 4.2.12.3.b & 4.2.12.5.a & Figures 4-19, 4-21, and 4-22
Repeated: Description of Damage, Critical Factors & Appearance & Morph of Dam
39b. Dissimilar Metal Weld Cracking (DMW) is most common in:

A) Carbon steel to Alloy 625 B) Carbon steel to Monel
C) Carbon steel to 316 Stainless D) Carbon steel to Low Alloy steel
Answer = C … See Paragraph 4.2.12.2  Affected Materials
39c. Dissimilar Metal Weld Cracking (DMW) occurs most often between ferritic and
austenitic materials because the coefficient of thermal expansion for SS is:
A) About 25 to 30% greater than CS B) About 25 to 30% less than CS
C) About 15 to 20% greater than CS D) About 15 to 20% less than CS
Answer = C … See Paragraph 4.2.12.3.b  Critical Factors
39d. DMW Cracking between ferritic and austenitic materials in a wet H2S environment:
A) Can be prevented by PWHT regardless of service temperature
B) Can be prevented by PWHT and limiting service to 510º F (260ºC)
C) Can be prevented by PWHT and limiting service to 600º F (315ºC) per API 582 guidelines
D) Cannot be prevented by PWHT
Answer = D … See Paragraph 4.2.12.3.g  Critical Factors
39e. Dissimilar metal weld cracking forms at the toe of the weld in the HAZ of the:
A) Ferritic material B) Austenitic material C) Martensitic material D) None of these
Ans: A … Ref: 4.2.12.5.a  Figures 4-19/21/22 … A/MOD
39f. Regarding Dissimilar Metal Weld Cracking, which statement(s) below are correct
about the proper techniques to be used during Inspection & Monitoring?
A) In fired heater tubes, the cracks form primarily from the outside (So use VT, MT and PT)
B) Environmental cracking can result in surface breaking cracks initiating on ID surfaces
C) Environmental cracking can be detected using Acoustic Emission (AE) methods
D) Environmental cracking can be detected using UT methods
Answer: B … API 571, Para. 4.2.12.7 … ET is not possible … Insp & Monitoring

66
DM # 40 … HYDROGEN STRESS CRACKING (HF)

40a. A form of environmental cracking that can initiate on surfaces of high strength low
alloy steels and carbon steels with highly localized zones of high hardness in the weld metal
and HAZ as a result of exposure to aqueous HF acid service is called:
A) Sulfide stress cracking B) Hydrogen stress cracking

C) Caustic stress cracking D) Hydrogen induced cracking
Answer: B … Ref: 5.1.4.2.1  Hydrogen Stress Cracking (HF) … Descrip of Damage
40b. Critical factors in causing hydrogen stress cracking (HF) are:
A) Steel hardness and stress only B) Steel hardness, strength, and stress
C) Alloy composition & temperature only D) Alloy composition, strength & temperature
Answer: B … Reference: 5.1.2.4.3.a … Critical Factors
40c. Piping exposed to HF acid is subject to hydrogen stress cracking if hardness:
A) > 200 BHN B) > 225 BHN C) > 237 BHN D) 241 BHN
Answer: C … Ref: 5.1.2.4.3.b Rockwell C 22 = BHN 237 … Critical Factors
40d. Hardness levels above what Rockwell & BHN values create a high susceptibility for
hydrogen stress cracking (HF) in Carbon Steel and low alloy steels?
A) Rockwell C 15 or 200 BHN B) Rockwell C 20 or 225 BHN

C) Rockwell C 22 or 237 BHN D) Rockwell C 23 or 241 BHN
Answer: C … Reference: 5.1.2.4.3.b … Critical Factors
40e. The best method to determine susceptibility of materials to Hydrogen Stress Cracking
in HF Service is:
A) Heat Treatment B) Tensile strength C) Impact Testing D) Hardness Testing
Answer = D … See Para. 5.1.2.4.3.b (Critical Factors) & Prevention & Insp & Monitoring
40f. In HF acid service, which statement is TRUE regarding affected equipment?
A) All exposed piping/equipment with hardness levels up to the recommended limit can crack
B) High strength low alloy steels (ASTM A193-B7 bolts) are not susceptible to cracking
C) ASTM A193-B7 bolts are usually not susceptible, even if they are over torqued
D) ASTM A193-B7M bolts are susceptible if over torqued
Ans = D … Para 5.1.2.4.4.a/b/c  HF Cracking (Aff. Equip)  Calibrated Torque wrench

67
DM # 41 … DEALLOYING
41a. Dealloying in brass is visually evident and may be identified by a color change:
A) Brass changes to a reddish color

B) Brass changes to a grayish color
C) Brass changes to an orangish color
D) Brass changes to a dull white color
Answer = A … See Paragraph 4.3.11.7.b  Dealloying … Insp & Monitoring
41b. Dealloying of Monel (HF acid environment) results in:
A) Denickelfication B) Destannification
C) Graphitic Corrosion D) None of these
Answer = A … See Paragraph 4.3.11.3.d & Table 4-7  Dealloying … Critical Factors
41c. Dealloying of gray cast iron is visually evident and may be identified by:
A) No change or thickness change but material is soft and can be cut by a knife
B) A color change to charcoal gray and the material may be cut by a knife
C) A color change to black and the material is cracked and deteriorated
D) A color change to black and the soft material may be cut by a knife
Answer = B … See Paragraph 4.3.11.7.c  Dealloying … Insp & Monitoring
41d. All of the factors that influence Dealloying include the composition of the alloy and
exposure conditions that include:
A) Temperature, oxygen levels, and pH

B) Temperature, degree of aeration, pH and exposure time.
C) Temperature, oxygen levels, pH, and the specific gravity of the product
Answer = A … See Paragraph 4.3.11.3.a  Dealloying … Critical Factors

68
DM # 42 … CO² CORROSION
42a. CO2 Corrosion results when CO2 dissolves in water to form:
A) Carbolic Acid
B) Carbonic Acid
C) HCL acid
D) None of these
Answer: B … API 571, Para. 4.3.6.1  CO2 Corrosion … Description of Damage
43b. CO2 Corrosion affects:
A) Carbon Steels only

B) Carbon Steels and Low alloy Steels
C) Carbon Steels, Low alloy Steels, and Stainless Steels
D) Carbon Steels, Low alloy Steels, Stainless Steels and Nickel Steels
Answer: B … API 571, Para. 4.3.6.2  CO2 Corrosion … Affected Materials
43c. Severe internal grooving with deep pitting was found at the bottom of a 4-inch CS
elbow (area of turbulence) in steam condensate system. Damage was most likely caused by:
A) Erosion/Corrosion B) Chloride Corrosion

C) Ammonium Bisulfide Corrosion D) CO² Corrosion
Ans: D … Par. 4.3.6.4.a & 4.3.6.5.b  CO2 Corrosion … Affected Units & Insp & Monitor
4.3.6 CO² Corrosion

4.3.6.5 Appearance or Morphology of Damage
a) Localized thinning and/or pitting corrosion of carbon steel (Fig 4-41, Fig 4-42 and Fig 4-43).
b) Carbon steel may suffer deep pitting and grooving in areas of turbulence (Figure 4-44).
c) Corrosion generally occurs in areas of turbulence/impingement & sometimes in piping
weld roots.
OR …
4.2.14 Erosion/Erosion – Corrosion
a) Erosion and erosion-corrosion are characterized by a localized loss in thickness in the form of pits,
grooves, gullies, waves, rounded holes and valleys. These losses often exhibit a directional pattern.
b) Failures can occur in a relatively short time.

69
DM # 43 … CORROSION FATIGUE
43a. Deaerators that have not been PWHT’d can experience this damage mechanism:
A) Caustic SCC
B) Corrosion Fatigue
C) Steam blanketing
D) Vibration-Induced Fatigue
Answer = B … See Paragraph 4.5.2.4.b  Corrosion Fatigue … Affected Equipment
43b. Corrosion Fatigue fractures are brittle and cracks are most often transgranular, as in
SCC, but not branched, and often results in (what appearance):
A) Craze crack appearance

B) Multiple parallel cracks
C) Condition called rabbit ears
D) None of these
Answer = B … See Paragraph 4.5.2.5.a  Corrosion Fatigue … Insp & Monitoring
43c. In cycling boilers, Corrosion Fatigue damage usually appears first on the:
A) On the water side of the buckstay (structural attachment)

B) On the fire side of the buckstay (structural attachment)
C) On economizer section lower end structural supports
Answer = A … See Paragraph 4.5.2.5.c  Corrosion Fatigue … Insp & Monitoring

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DM # 44 … FUEL ASH CORROSION

44a. Fuel Ash corrosion typically occurs with fuel oil or coal that is contaminated with:
A) A combination of sulfur, sodium, potassium and/or vanadium

B) Vanadium and sodium
C) Sulfur and sodium
D) None of these
Answer = A … See Para 4.4.6.1.b  Fuel Ash Corrosion  Description of Damage
44b. The severity of Fuel Ash corrosion depends on all of these factors EXCEPT:
A) Type of fuel (with contaminant concentration)

B) Metal temperature
C) Oxygen content
D) Sulfur content
Answer = C … See Para 4.4.6.3.b  Fuel Ash Corrosion  Critical Factors
44c. Heaters burning fuel with contaminants (assume this is a fuel ash corrosion question)
will likely see damage to (Corrosion is more likely in):
A) Radiant Section Tubes

B) Convection Section tubes
C) Tube Hangers & Supports
D) Burner Section & associated equipment
Answer = C … See Para 4.4.6.4.c  Fuel Ash Corrosion  Affected Units or Equipment

c) For oil ash corrosion of superheaters and reheaters, the appearance of the ash deposit will be in
at least two distinct layers. The important deposit is adjacent to the component, which will have a
dark gray or black appearance at room temperature. As the liquid sulfates sinter the corrosion
debris to the surface, a hard, glassy, tenacious scale is formed. When removed, the surface of the
steel will have an “alligator-hide” appearance (Figure 4-127 and Figure 4-128) as shallow
grooves will have penetrated the steel in a cross-hatched pattern.
Answer = C … See Para 4.4.6.5.c  Fuel Ash Corrosion  Appearance

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DM # 45 … AMINE CORROSION
45a. The primary cause of Amine corrosion is:
A) Amine solution temperatures greater than 250°F (121°C)

B) Dissolved acid gases (CO2, H2S) and contaminants
C) Amine concentration levels and free water
D) Heat Stable amine salts and free water
Answer = B … See Para. 5.1.1.1.1.  Amine Corrosion (Description of Damage)
45b. For CS in amine service, common velocity limits are generally limited to:
A) 3 – 6 ft/sec (0.9 – 1.8 m/sec) for rich amine and 20 ft/sec (6.0 m/sec) for lean amine
B) 4 – 8 ft/sec (1.2 – 2.4 m/sec) for rich amine and 10 ft/sec (3.0 m/sec) for lean amine
C) 6 – 9 ft/sec (1.8 – 2.7 m/sec) for rich amine and 15 ft/sec (4.5 m/sec) for lean amine
D) 8 – 10 ft/sec (2.4 – 3.0 m/sec) for rich amine and 30 ft/sec (9.0 m/sec) for lean amine
Answer: A … Ref: 5.1.1.1.3.g  Amine Corrosion … Critical Factors
45c. Amine corrosion depends on Critical Factors that include design, operating practices,
the type of amine, amine concentration, temperature and:
A) Pressure B) Velocity
C) Stress D) None of the above (nothing else)
Answer: B … Ref: 5.1.1.1.3.a … Amine Corrosion … Critical Factors
45d. Which alkanolamine system is the most aggressive in causing amine corrosion?
A) Monoethanolamine (MEA)
B) Diglycolamine (DGA)
C) Diethanolamine (DEA)
D) Methyldiethanolamine (MDEA)
Answer: A … Ref: 5.1.1.1.3.c …  Amine Corrosion … Critical Factors
45e. Preferential weld attack is not likely in which of these services?

A) Amine Corrosion, particularly MEA & Lean Amine Services
B) Sulfuric Acid Corrosion
C) HF Acid Corrosion
D) Caustic Corrosion
Answer: D … Ref: 5.1.1.1.5.a & Figures 5.1/2/3  Note: Four DMs in API 571 exhibit
preferential weld corrosion … Missing in most Insp Programs … See CO 2 Corrosion

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DM # 46 … CORR UNDER INSL (CUI) … 14 Q&A

46a. CUI affects CS & Low alloy steels operating at this metal temperature range:
A) Ambient Temp to a maximum temperature limit of 212F (100C)

B) Ambient Temp to a maximum temperature limit of 250F (121C)
C) 10F (-12C) to a maximum limit of 350F (175C)
D) 140F (60C) to a maximum limit of 400F (205C)
ANS: C … API 571 4.3.3.3.aCUI Critical Factor Susceptible Temp Range MUST KNOW
46b. CUI affects Austenitic & Duplex SS operating at this metal temperature range:
C) 10F (-12C) to a maximum limit of 350F (175C)
D) 140F (60C) to a maximum limit of 400F (205C)
ANS: D … API 571 4.3.3.3.aCUI Critical Factor Susceptible Temp Range MUST KNOW
46c. CUI becomes more severe at this metal temperature range, where water is less likely to
vaporize and the insulation stays wet longer:
C) Boiling point of 212F (100C) to a maximum limit of 250F (121C)
D) Boiling point of 212F (100C) to a maximum limit of 350F (175C)
ANS: D … API 571 4.3.3.3.bCUI Critical Factor Susceptible Temp Range MUST KNOW
46d. Regarding CUI, corrosion rates will:

A) Decrease with increasing metal temps up to the point where water evaporates quickly
B) Increase with increasing metal temps up to the point where water evaporates quickly
C) Stay the same regardless of the metal temperature and rate of water evaporation
D) Increase with increasing metal temps up to 212F (100C), the boiling point
ANS: B … API 571 4.3.3.3.bCUI Critical Factor Susceptible Temp Range MUST KNOW
46f. Four Critical Factors for CUI are:

A) Design of insulation system, insulation type, coating system quality, and temperature
B) Design of insulation system, insulation type, coating system quality, and environment
C) Design of insulation system, coating system quality, temperature and environment
D) Design of insulation system, insulation type, temperature and environment
ANS: D … API 571 4.3.3.3.c  CUI Critical Factors  Must Know these 4 CUI CFs!

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46g. Which statement regarding CUI Critical Factors is FALSE?
A) Insulation materials that wick are desirable because they prevent moisture entrapment
B) Poor design or installations that allow water to become trapped will increase CUI
C) Equipment operating below the water dewpoint increases the risk of CUI
D) Cyclical thermal operation or intermittent service can increase CUI
ANS: A … API 571 4.3.3.3.d/e/f/g  CUI Critical Factors  MUST KNOW WICKING
CUI term “wick” or “wicking” … What does it mean? Uhhhh, keeps water out!
You missed # 46g didn’t you? Wicking means that an insulation “HOLDS WATER” …
Like Calcium silicates and fibrous insulations  These “wicking” type insulations are
severely limited in high temperature services above 200F (93C) in most Oil Companies!
46h. Which is NOT an example of environments providing airborne contaminants that can
accelerate CUI?
A) Marine environments provide chlorides

B) Cooling tower drift provides chlorides
C) Plants with high annual rainfall
D) Stack emissions provide SO2
ANS: C … API 571 4.3.3.3.j CUI Critical FactorsAirborne Contaminants Should know
46i. Critical Environmental Factors for CUI do NOT include:
A) Insulation System Design & Type

B) Chlorides in Marine Environment
C) Industrial pollution (SO², etc)
D) Humidity & Rainfall
ANS: A … API 571 4.3.3.3.j CUI CFEnvironmental Factors for CUI  Should Know
46j. Mitigation (Prevention) of CUI is best achieved by:
A) Carefully planned periodic inspections after proper design and installation of insulation
B) Employment of quality coatings and maintaining insulation sealing/vapor barriers
C) Employment of quality coatings and careful visual exam of insulation coverings
D) Proper design and installation of insulation
ANS: B … API 571, 4.3.3.6.a  CUI Prevention … Should know

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46k. CUI Inspection plans should have a structured and systematic approach starting with:
A) Random visual examinations followed by supplemental NDE and strategic insulation removal
B) Carefully planned examinations supplemented by NDE and strategic insulation removal
C) Risk-based Inspection methods using supplemental NDE as per Inspection Plans
D) Prediction and analysis, then looking at more invasive procedures
ANS: D … API 571 4.3.3.7.a bullets  CUI Insp & Monitor CUI Insp Plan Must Know
46L. Inspection plans for CUI should consider all of these factors EXCEPT:
A) Operating temperature of system

B) Type and age/condition of coating
C) Type and age/condition of insulation material
D) Inspection strategies previously used by Owner/User
ANS: D … API 571 4.3.3.7.a CUI Insp Plan Insp & Monitoring  Must Know
46m. Areas of concern for CUI (having high moisture) that require inspection &
monitoring do NOT include:
A) Areas with deluge systems and areas near supplemental cooling with water spray
B) Areas down-wind from cooling towers and areas near steam vents
C) Areas where acid vapors are present
D) Areas adjacent to firewater tanks
ANS: D … API 571, 4.3.3.7.d  CUI Inspection and Monitoring locations MUST KNOW
46n. Inspection plans for CUI use Inspection techniques to detect wet insulation including:
A) Real-time profile radiography and neutron backscatter techniques

B) Infrared thermography and neutron backscatter techniques
C) Infrared thermography and real-time profile radiography
D) Hammer test and partial stripping
ANS: B … API 571 4.3.3.7.e.2 bullets  CUI Insp & Monitoring  Must Know

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DM # 48 … AMMONIA SCC
48a. Aqueous solutions containing NH³ causes SCC in what alloys?
A) Ti B) Cu C) Ni D) Chrome
Answer: B … API 571, Para. 4.5.4.1.a – Ammonia SCC  Description of Damage
What is NH³? It is Ammonia, a byproduct of natural gas production!

Expect similar type questions as this for each of the unique SCC mechanisms listed above.
Which mechanism above applies to this question? See 4.5.4 below for Ammonia SCC.
4.5.4 Ammonia Stress Corrosion Cracking
4.5.4.1 Description of Damage
a) Aqueous streams containing ammonia may cause Stress Corrosion Cracking (SCC) in
some copper alloys. …
b) Carbon steel is susceptible to SCC in anhydrous* ammonia.  Discuss*
Highlight additional sections likely for Exam questions
48b. Which method below can prevent Ammonia SCC in non-PWHT’d carbon steels?
A) High strength steels should be used

B) Addition of small quantities of water to the ammonia
C) Assure sufficient oxygen is available to the process feed
D) None of these are correct because PWHT is always required
Answer: B … API 571, Para. 4.5.4.6.b – Ammonia SCC  Prevention/Mitigation

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DM # 49 … COOLING WATER CORR  12 Q&A

1. Critical factors for COOLING WATER CORROSION include all of these EXCEPT:
A) Carbon Dioxide content
B) Fluid temperature and fluid velocities
C) Type of water used (fresh, brackish, salt water)
D) Type of cooling system (once-through, open circulating, closed circulating)
Answer = A … See Para. 4.3.4.3.a … Oxygen content (Critical Factors)
2. Increasing cooling water outlet temps and or process side inlet temps tend to:
A) Increase corrosion rates only
B) Decrease corrosion rates and oxygen content
C) Increase corrosion rates as well as fouling tendency
D) Decrease corrosion rates as well as fouling tendency
Answer = C … See Para. 4.3.4.3.b … (Critical Factors)
3. Regarding CS corrosion rates, increasing cooling water oxygen content tends to:
A) Increase corrosion rates
B) Decrease corrosion rates
C) Neither increases nor decreases corrosion rates regardless of any other factors
D) May increase or decrease corrosion rates depending upon a variety of other factors
Answer = A … See Para. 4.3.4.3.c  Cooling water corrosion … (Critical Factors)
4. Which statements regarding temps, scaling and cooling water corrosion are false?
A) If process side temperature is ˃ 140°F (60°C), a scaling potential exists with fresh water
B) Scaling becomes more likely as process temps decrease and cooling water inlet temps fall
C) Brackish and salt water outlet temps above about 115°F (46°C) may cause serious scaling
D) 300 Series SS can suffer pitting corrosion/crevice corrosion/SCC in fresh/brackish/salt water
Answer = B … See Par. 4.3.4.3.d/h … (Critical Factors)
5. Which statements regarding cooling water corrosion in fresh/brackish systems are false?
A) Accelerated corrosion can result from dead spots or stagnant areas if cooling water is used on
the tube side of condensers/coolers rather than the preferred shell side.
B) Velocity limits depend on tube material & water quality (velocity should not cause corrosion)
C) Velocities should be high enough to minimize fouling and the “drop out” of deposits
D) Velocities below 1 m/s are likely to result in fouling/sedimentation/increased corrosion
Answer = A … See Par. 4.3.4.3.f/g  shell side of condensers … preferred tube side … (CF)
6. Which statements regarding cooling water corrosion critical factors are false?
A) Copper/zinc alloys can suffer SCC if ammonia compounds are in the water or on process side
B) 300 Series SS can suffer pitting corrosion/crevice corrosion/SCC in fresh/brackish/salt water
C) Copper and zinc alloys can suffer dezincification in fresh, brackish and salt water systems
D) ERW CS may suffer severe weld and/or HAZ corrosion in salt water
Answer = D … See Par. 4.3.4.3.h/i/j … (Critical Factors)
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DM # 49 … COOLING WATER CORR  12 Q&A

7. In all applications across all industries, cooling water corrosion is a concern with:
A) Condensers and evaporators and water-cooled heat exchangers
B) Water-cooled heat exchangers and condensers only
C) Water-cooled heat exchangers and cooling towers
D) Water-cooled HEs, condensers & cooling towers
Answer = C … See Par. 4.3.4.4 … (Affected Units or Equipment)
8. Cooling water corrosion damage may be any one of the following except:
A) Microbiologically Induced Corrosion (also known as MIC)
B) General corrosion or pitting corrosion
C) Stress corrosion cracking
D) Scaling
Answer = D … See Par. 4.3.4.5.a  Fouling … (Appearance or Morphology of Damage)
9. Which of the following items regarding cooling water corrosion appearance or
morphology of damage are false?
A) General or uniform corrosion of carbon steel occurs when dissolved CO² is present.
B) Localized corrosion may result from under deposit corrosion, crevice corrosion or MIC
C) Deposits or crevices can lead to under deposit or crevice corrosion of any affected material
D) Nozzle inlets/outlet & tube inlet corrosion may be due to flow induced corrosion or erosion
Answer = A … See Par. 4.3.4.5.a  dissolved oxygen … (Appearance or MOD)
10. Cooling water should be monitored for variables that affect corrosion and fouling
including all of the following EXCEPT:
A) The pH, oxygen content and cycles of concentration
B) Hydrocarbon contamination and process leaks
C) Biocide residual and biological activity
D) Cooling water inlet temperatures
Answer = D … See Par. 4.3.4.7.a  outlet temps … (Inspection & Monitoring)
11. Periodic calculation of this variable (heat exchanger performance measurement) will
provide information on scaling and fouling?
A) F-Factors B) P-Factors C) S-Factors D) U-Factors
Answer = D … See Par. 4.3.4.7.b … (Inspection & Monitoring)
12. Cooling water corrosion at ERW weld areas appears as:

A) Grooving along weld fusion lines B) Preferential weld zone attack/wastage
C) Localized linear pitting D) None of these
Answer = A … Par. 4.3.4.5.f  Appearance  Grooving along weld fusion lines

78
DM # 50 … BOILER WATER COND. CORR. (8 Q&A)
50a. Corrosion in Boiler Feedwater & Condensate Return systems is usually the result of:
A) Poor water quality (Total dissolved solids or TDS count is too high)
B) pH variations causing localized attack (from acids, amines)
C) Excessive boiler heating and steam blanketing or DNB
D) Dissolved gases oxygen and carbon dioxide
ANS: D … API 571 4.3.5.3.a BW Cond. Corr CF = Dissolved Oxygen & CO2 Must Know
50b. Boiler Water Condensate Corrosion resulting from dissolved Oxygen & CO2 leads to:
A) General corrosion (by Oxygen) and localized corrosion (by CO2)

B) Localized corrosion (by Oxygen) and general corrosion (by CO2)
C) Pitting corrosion (by Oxygen) and carbonic acid corrosion (by CO2)
D) General corrosion (by Oxygen) and carbonic acid corrosion (by CO2)
ANS: C … API 571 4.3.5.3.a BW Cond. Corr CF = Dissolved Oxygen & CO2 Must Know
50c. Boiler Water Condensate Corrosion Critical Factors are:
A) Dissolved gas concentration (Oxygen, CO2), pH, Temp, Feedwater quality/treating system
B) Dissolved gas concentration (Oxygen, CO2) and Feedwater quality/treating system
C) Temperature, pH, Feedwater quality/treating system
D) pH and Feedwater quality/treating system
ANS: A … API 571 4.3.5.3.b BW Cond. Corr CF = 5 Critical Factors  Should Know
50d. Boiler corrosion protection is accomplished by laying down/continuously maintaining:
A) An oxygen scavenger film (correct treatment) based on feedwater analysis

B) A layer of protective film composed of oxygen scavenger and iron ions
C) A layer of protective FE3O4 (Magnetite)
D) A steam blanket with no DNB
ANS: C … 571 4.3.5.3.bBW Cond Corr CFMust Know magnetite layer protects boiler

79
DM # 50 … BOILER WATER COND. CORR. (8 Q&A)

50e. Boiler Water Condensate Corrosion from oxygen tends to be (is usually):
A) General even corrosion and metal loss

B) Smooth grooving of the equipment walls
C) Localized corrosion that shows up at predictable locations in the system (near a temp rise)
D) Pitting type damage that can show up anywhere in a system (breaks in scavenging treatment)
ANS: D … API 571 4.3.5.5.aBW Cond Corr AppearanceMust know on previous exam
50f. Boiler Water Condensate Corrosion from oxygen is particularly aggressive in

equipment such as closed heaters and economizers where:
A) There is a rapid water temperature rise

B) The phenomenon known as DNB occurs
C) CO2 corrosion combines with oxygen corrosion
D) The effect of Steam blanketing is a major concern
ANS: A … API 571 4.3.5.5.a BW Cond Corr AppearanceShould know expect this!
50g. Corrosion in Condensate return systems from CO2 tends to be (is usually):
A) General even corrosion and metal loss

B) Smooth grooving of the condensate return piping walls
C) Localized corrosion that shows up at predictable locations in the system (near a temp rise)
D) Pitting type damage that can show up anywhere in a system (breaks in scavenging treatment)
ANS: B … API 571 4.3.5.5.aBW Cond Corr AppearanceMust know on previous exam
50h. Common method of Insp & Monitoring for Boiler Water Condensate Corrosion is:
A) Analysis of pH
B) Analysis of water
B) Analysis of treatment chemicals
C) Analysis of operation process variables
ANS: B … API 571 4.3.5.7.a BW Cond Corr CFMust KnowAsked on 510 exams
Boiler Water Condensate Corr. … You will get 1 of these 8 for sure!!! Hmmm!

80
DM # 51 Microbiologically-Induced Corrosion (MIC) … (9 Q&A)

51a. This DM is a form of corrosion caused by living organisms such as bacteria, algae or
fungi and is often associated with the presence of tubercles or slimy organic substances.
A) Microbiologically Induced Corrosion

B) Boiler water condensate corrosion
C) Cooling water corrosion
D) Sour water corrosion
ANS: A … API 571 4.3.8.1.a  MIC … Description of damage
51b. Mic affects:
A) Carbon steels only B) Carbon and low alloy steels only

C) Most common construction materials D) CS & LA steels and 300 & 400 Series SS
ANS: C … API 571 4.3.8.2  MIC … Affects all common materials of construction
51c. MIC is usually found in aqueous environments or services where water is:
A) Always or sometimes present and especially where stagnant or low-flow conditions exist
B) Always present and adequately treated with biocides, ozone, UV light or other means
C) Always present and even in high velocity areas with crevices existing
D) Always present and subject to low velocities
ANS: A … API 571 4.3.8.3.a  MIC … Critical Factors  MUST KNOW!!!
51d. This DM is usually found in aqueous environments or services where water is

sometimes or always present, especially where stagnant or low-flow conditions exist:
A) Microbiologically Induced Corrosion

B) Boiler water condensate corrosion
C) Cooling water corrosion
D) Sour water corrosion
ANS: A … API 571 4.3.8.3.a  MIC … Critical Factors
51e. Regarding MIC, different organisms thrive on different nutrients incl. inorganic
substances (Sulfur, H²S), and organic substances (Hydrocarbons, Organic acids). In
addition, all organisms require a source of what elements for growth?
A) Carbon, nitrogen and water B) Carbon, nitrogen and oxygen

C) Carbon, nitrogen and manganese D) Carbon, nitrogen and phosphorous
ANS: D … API 571 4.3.8.3.d  MIC … Critical Factors Should know!

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DM # 51 Microbiologically-Induced Corrosion (MIC) … (9 Q&A)

51f. MIC is usually observed as:
A) General corrosion and isolated pitting filled with organisms
B) Localized deep pits containing scale that shields the organisms
C) Localized pitting under deposits or tubercles that shield the organisms
D) Deep grooving with tightly adherent deposits that shield the organisms
ANS: D … API 571 4.3.8.5.a MIC … Appearance … MUST KNOW TUBERCLE
51g. MIC damage is often characterized by:
A) General corrosion and isolated pitting filled with organisms

B) Cup-shaped pits in CS (Halo effect) or subsurface cavities in SS
C) Localized deep pits containing scale and deposits from the organisms
D) Deep grooving with tightly adherent deposits that shield the organisms
ANS: B … API 571 4.3.8.5.b & 6 Figs MIC Appearance! MUST KNOW HALO EFFECT
51h. MIC prevention is accomplished by treatment using any of these EXCEPT:
A) Reverse Osmosis B) Proprietary compounds

C) Ozone and ultraviolet light D) Biocides (such as chlorine, bromine)
Answer: A … API 571, Para. 4.3.8.6.a  MIC … Prevention/Mitigation
407. Inspection and Monitoring for MIC treatment effectiveness in Cooling Water (CW)
systems does not include:
A) Measure of microbe counts B) Measure of biocide residuals

C) Visual appearance checking D) Special probes to monitor fouling
Answer: D … API 571, Para. 4.3.8.7.a/b  MIC … Inspection & Monitoring
MIC! You will get 1 of the 9 on API 571 exam, Wiggum! My “halo” is ready!!!
Are you are turning into an angel with a halo, Wiggie? I worked with Rene Carrera
in the Juaymah Plant and we hydrotested hundreds of Fin Fan Coolers that we mishandled
on shipment. We left the hydrotest water inside & didn’t follow SAES-A-007 Layup Rules!
MIC ate hundreds of bundles up in those Fin Fans and it cost COMPANY & Contractor a
fortune in replacement costs and delays on the Project … MIC is good job security for me!
Get lost, Babu! … Before I get my inspection hammer out and show you some “stars”
End of DM # 51  How did you do on the 9 MIC Qs?

82
DM # 52 … LIQUID METAL EMBRITTLEMENT

52a. LME due to Mercury (Fire melts gauge/ Mercury drips on pipe) affects:
A) High Strength Steel B) 300 Series SS
C) Carbon Steel D) Aluminum & Copper Alloys
Question # 63 = D
4.5.5 Liquid Metal Embrittlement (LME) … 4.5.5.3 Critical Factors
a) LME occurs in very specific combinations of metals in contact with low melting point metals
such as zinc, mercury, cadmium, lead, copper and tin. Typical combinations of industrial
significance are shown in Table 4-7.  You should know this Table!!!  Discussion: Use
Black Iron Scaffolding
52b. LMC can occur under all of these conditions EXCEPT (Select false statement):
A) When 300 series SS alloys come in contact with zinc
B) When copper & aluminum alloys come in contact with mercury
C) When high strength steels come in contact with cadmium and lead
D) LMC is not a recognized term for damage known as Liquid Metal Embrittlement
Answer: D … Ref: 4.5.5.3 & Table 4-7 & Fig 4-96/97 & 4.5.5.4.b … APP & MOD LMC (is
also referred to) = LME = Liquid Metal Embrittlement  4.5.5.8.a/b
52c. Galvanized steel components should not be welded to Stainless steel because:
A) DMW cracking will very likely be the result
B) Galvanic corrosion will occur
C) LME can result
Answer: D … Ref: 4.5.5.3 & Table 4-7 & Fig 4-96/97 & 4.5.5.4.b … APP & MOD LMC (is
also referred to) = LME = Liquid Metal Embrittlement  4.5.5.8.a/b

83
DM # 53 … GALVANIC CORROSION
Galvanic Series Table below (See page 4-103)

84
DM # 53 … GALVANIC CORROSION
53: Using the table on the previous page, which of the following combinations of metals in
contact with one another and exposed to a marine (seawater) environment will experience
the greatest amount of corrosion?
A) Copper-Nickel to Bronze connection B) Steel to Aluminum connection

C) Steel to Titanium connection D) Brass to Bronze connection
Answer = C … Correct = materials that are the “farthest apart” on a Galvanic Series Chart will
experience the greatest corrosion at the weaker anodic or more active material, in our case, Steel.
It is expected that you may find a similar question on your exam, so you must know this!
Instructor will use similar cases for practice in the course!  2 m rule for 30%
extra coating applies to all thin filmed coatings (≤ 500 microns or 20 mils) where anodes attach
EXERCISE 53 … GALVANIC CORROSION (8 Qs)

1. Which of these is not a critical factor in galvanic corrosion?
A) The presence of an electrolyte

B) An electrical connection between the anode and cathode
C) Dissimilar alloys (anode and cathode) in contact with one another
D) Dissimilar alloys (anode and cathode) in contact with an electrolyte
Answer: C … Ref: 4.3.1.3.a  Galvanic Corrosion (Know the 3 Critical Factors)
2. Corrosion rates of anodes will be less (less affected) if there is a:
A) Larger contact surface between dissimilar metals

B) Small anode to cathode ratio
C) Large anode to cathode ratio
Answer: C … Ref: 4.3.1.3.e.1/2  Galvanic Corrosion (CF) Anode to cathode ratios
3. A form of corrosion that can occur at the junction of dissimilar metals when they are
joined together in a suitable electrolyte, such as a moist or aqueous environment, or soils
containing moisture is called:
A) Dissimilar metal corrosion B) Sour water corrosion

C) Soil Corrosion D) Galvanic Corrosion
Answer: D … Reference: 4.3.1.1  Galvanic Corrosion is correct (Description of Damage)

85
EXERCISE 53 … GALVANIC CORROSION (8 Qs)

4. For galvanic corrosion to occur, which of these is NOT one of three conditions to be met?
A) Presence of an electrolyte or fluid that can conduct a current

B) Two differing materials or alloys (anode & cathode) in contact with an electrolyte
C) Exposed surface areas between the anodic material and the cathodic material exist
D) An electrical pathway or connection must exist between the anode and the cathode
Answer: C … Ref: 4.3.1.3.a  Galvanic Corrosion = (Three Critical Factors)
5. Which of the following statements is NOT TRUE regarding galvanic corrosion?
A) If the active material were coated, a large cathode to anode area can accelerate corrosion of
the anode at any breaks in the coating
B) If there is a galvanic couple (thread joint, etc), the less noble material may need to be coated
C) Corrosion rates of the anode will be less affected if there is a large anode to cathode ratio
D) Corrosion rates of the anode can be high if there is a small anode to cathode ratio
Answer: B … Reference: 4.3.1.3.e.1/2/3  Anode to cathode ratio … (Critical Factors)
6. Which of the following statements is NOT TRUE regarding the appearance or

morphology of damage for galvanic corrosion?
A) Anode corrosion may be significantly lower immediately adjacent to the cathode connection
B) The more active material may have the appearance of a crevice, groove, or pitting corrosion
C) Damage occurs where two materials are joined at welded or bolted connections
D) The more active material can suffer generalized loss in thickness
Ans: A … Ref: 4.3.1.5.a/b/c  significantly higher … (App or Morphology of Dam.)
7. Galvanic corrosion is the principle used in galvanized steel, where the Zinc (Zn) corrodes
preferentially to protect the underlying carbon steel. (If there is a break in the galvanized
coating, a large anode to small cathode area prevents accelerated corrosion of the steel).
This anode-to-cathode relationship reverses at water temperatures over about:
A) 150°F (66°C) B) 200°F (93°C)

C) 210°F (99°C) D) None of these temperatures as it never reverses
Answer: A … Reference: 4.3.1.6.e  (Prevention/Mitigation)
8. Which insp. & monitoring method(s) are very effective for detecting galvanic corrosion?
A) Visual inspection only B) Visual inspection and RT
C) Visual inspection and UT thickness D) Visual inspection, RT and UT thickness
Answer: C … Reference: 4.3.1.7  (Inspection & Monitoring)

86
DM # 54 … MECHANICAL FATIGUE
54a. Which of these is NOT a Critical factors related to Mechanical Fatigue?
A) Geometry of the component

B) Time in service and exposure
C) Stress levels & number of cycles
D) Material properties such as strength, hardness, and microstructure
Answer: B … API 571, Para. 4.2.16.3 – Mechanical Fatigue Question
54b. Regarding the appearance or morphology of Mechanical Fatigue, the signature mark
of fatigue failure will typically appear as:
A) Single clam shell fingerprint with vertical straight lines directly below the crack initiation site
B) Single clam shell fingerprint with rings called beach marks coming from a crack initiation site
C) Concentric lines throughout the entire cross-sectional area
Answer: B … API 571, Para. 4.2.16.5.a & Figures 4-30/31/32/33 – Mech Fatigue Question
54c. Most important factor in determining component’s resistance to Mech Fatigue is:
A) Material
B) Design
C) Operation
D) Time
Answer: B … API 571, Para. 4.2.16.3.a – Mechanical Fatigue  Critical Factors
54d. The best defense against fatigue cracking is:
A) Use of the proper Materials in construction (strength, ductility)

B) Following careful operational practices to minimize stresses
C) Timely inspections
D) Good design
Answer: D … API 571, Para. 4.2.16.6.a – Mechanical Fatigue  Prev & Critical Factors

87
DM # 55 … NITRIDING
55a. A hard, brittle surface layer that develops on some alloys due to exposure to high
temperature process streams containing high levels of ammonia or cyanides is known as:
A) Nitriding B) Ammonia Stress Corrosion Cracking

C) Metal Dusting D) Titanium Hydriding
Answer = A … See Para. 4.4.7.1 … Nitriding (Description of Damage)
55b. Nitriding begins above 600°F (316°C) and becomes severe above (what temperature):
A) 900°F (482°C)
B) 770°F (410°C)
C) 800°F (427°C)
D) None of these
Answer = A … See Paragraph 4.4.7.3.c … Nitriding (Critical Factors)

a) Nitriding is usually confined to the surface of most components and will have a dull,
dark gray appearance. However, during initial stages of nitriding, damage is seen only with
metallography as shown in Figure 4-74, Figure 4-75 and Figure 4-76.
55a. What damage mechanism may be suspected if the service changed the surface color of
the piping to dull gray and a BHN value of 400 to 500 was found?
A) Nitriding B) Ammonia Stress Corrosion Cracking

C) Metal Dusting D) Titanium Hydriding
Answer = A … See Para. 4.4.7.7 … Nitriding (Inspection & Monitiring)

88
DM # 56 … VIBRATION-INDUCED FATIGUE  10 Q&A

56a. Cause for cracking on ¾” NPS CS high point vent on steam relief line is likely due to:
A) Mechanical Fatigue
B) Vibration-induced fatigue
C) Stress Corrosion Cracking
D) Original fabrication weld defect
Ans = B … See Para. 4.2.17.4/5/6  Vibration Induced Fatigue (Aff Units/App/Prevention)
56b. Critical factors in vibration-induced fatigue include all of the following except:
A) The amplitude of vibration

B) The frequency of vibration
C) Fatigue resistance of the component
D) Metal temperature of the component
Answer: D … Reference: 4.2.17.3.a … Critical factors
56c. A form of mechanical fatigue in which cracks are produced as the result of dynamic
loading due to water hammer or unstable fluid flow is called:
A) Corrosion fatigue B) Erosion-corrosion fatigue

C) Vibration-induced fatigue D) None of these are correct
Answer = C … See VIF, Para. 4.2.17.1 (Description of Damage)
56d. Which of the following is NOT a critical factor for vibration-induced fatigue?
A) Cracking is likely when the input load is synchronous with the component’s natural frequency
B) Cracking problems from vibration-induced fatigue usually initiate at stress raisers or notches
C) The amplitude and frequency of vibration as well as the fatigue resistance of the component
D) Excessive support or stiffening prevents vibration & possible cracking problems
Ans = D … See VIF, Para. 4.2.17.3.a/c … allows vibration and possible … (Critical Factors)
56e. Regarding vibration-induced fatigue, affected Units or Equip include all these except:
A) Socket welds & small bore piping at or near pumps and compressors that are not sufficiently
gusseted & any small bore bypass lines & flow loops around rotating & reciprocating equipment
B) Safety relief valves subject to chatter/fretting/premature pop-off/failure to operate properly
C) Branch connections with valves, drop control valves, and steam reducing stations
D) Heat exchanger tubes susceptible to vortex shedding
Answer = C … See VIF, Para. 4.2.17.4.a/b/c/d/e (Affected Units or Equipment)  Typo Ok

89
DM # 56 … VIBRATION-INDUCED FATIGUE  10 Q&A
56f. Which of these statements correctly identify appearance or morphology of damage for
Vibration-induced Fatigue (VIF)?
A) Crack initiating points occur in a high stress area (thread joint) or at a weld joint discontinuity
B) High skin temperatures (also hot spots) resulting from improperly installed anchor systems
C) Definite warning sign of VIF damage is loose refractory visible at low points
D) Definite warning sign of VIF damage is anchoring system exposure
Answer = A … See VIF, Para. 4.2.17.5.a/b (Appearance or Morphology)
56g. Which of these are NOT prev/mitigation measures for vibration-induced fatigue?
A) VIF can be eliminated or reduced by design / support use / vibration dampening equipment
B) Vortex shedding can be eliminated at control valve/safety valve outlets
C) Install gussets/stiffeners on small bore connections
D) Eliminate unnecessary small bore connections
Answer = B … See VIF, Para. 4.2.17.6.a/b/c/d … can be minimized (Prevention/Mitigation)
56h. Which of these are NOT insp & monitoring points for vibration-induced fatigue?
A) Surface inspection methods used (such as PT, MT) can be effective in a focused plan
B) Check for audible sounds of vibration from piping components (control valves & fittings)
C) Look for visible signs of vibration, pipe movement, or water hammer (Check pipe supports)
D) Insulation jacket damage (that can cause wet insulation) always indicates excessive vibration
Ans = D … See VIF, Para. 4.2.17.7.a/b/c/d … may indicate excessive (Insp & Monitoring)
56i. Inspection & Monitoring strategies for Vibration-Induced Fatigue should include all of
the following measures except:
A) Check for visible signs and evidence of vibration, pipe movement or water hammer
B) Check for insulation jacket damage (which is a definite indicator of excessive vibration)
C) Check for audible vibration sounds coming from piping components (control valves, fittings)
D) Measure pipe vibrations using special monitoring equipment, and conduct visual inspection
during transient conditions (startup, shutdowns, upsets, etc.) for intermittent vibrating conditions
Ans: B … API 571, Para. 4.2.17.7.a/b/c/d/g  e & f = Use surface NDE methods (PT, MT),
& check pipe supports & spring hangers on a regular schedule … Inspection & Monitoring
Note: Insulation jacket damage MAY indicate excessive vibration

90
DM # 57 … TITANIUM HYDRIDING
57. Amine unit OH condensate piping & HE’s made with Titanium alloys are most likely
damaged by:
A) Amine SCC B) Amine Corrosion
C) Dealloying D) Metal (Titanium) Hydriding
Ans = D … See Par 5.1.3.2.4.a  Titanium Hydriding … Affected Units or Equipment
57. Titanium should not be used in which of the services due to Titanium Hydriding:
A) Caustic and amine service should never use titanium (exchanger tubes, etc)
B) Amine & Sour Water service should never use titanium (exchanger tubes, etc)
C) Caustic & Alkylation service should never use titanium (exchanger tubes, etc)
D) Sour water & Alkylation service should never use titanium (exchanger tubes, etc)
Answer: B … Ref: 5.1.3.2.6.a … Prevention/Mitigation
57. When connected to a more anodic material, titanium may suffer severe:
A) Corrosion B) Hydriding
C) Stress D) None of these
Ans: B … Ref: 5.1.3.2.c  Titanium Hydriding over 165°F (74°C) – CF & P/M item b

91
DM # 58 … SOIL CORROSION  11 Q&A
58a. Deterioration of metals exposed to soils is referred to as:
A) MIC
B) Soil Corrosion
C) Atmospheric Corrosion
D) S/A Interface Corrosion
ANS: B … API 571, Para. 4.3.9.1  Soil Corrosion Description of Damage
58b. Soil corrosion affects:
A) Carbon steel, cast iron, & ductile irons

B) CS, cast & ductile irons, low alloy steels
C) CS, cast & ductile irons, low alloy & SS
D) All commonly used steels in the refining industry
ANS: A … API 571, Para. 4.3.9.2  Soil Corrosion … Affected Materials
58c. Which is not a critical factor in soil corrosion?
A) Cathodic protection and stray current drainage

B) Soil resistivity, soil type and homogeneity
C) Soil temperature, texture, and moisture
D) Coating type, age, and condition
ANS: C … Ref: 4.3.9.3.a  Soil Corr CF = Op temp + Moisture + O² availability)
58d. Soil resistivity is related to:
A) Dissimilar soil measurements

B) Differential aeration corrosion cells
C) Galvanic corrosion and stray electrical currents
D) Soil moisture content and the amount of dissolved electrolytes in soil’s water
ANS: D … API 571, Para. 4.3.9.3.c – Soil Corrosion … Critical Factors

92
58e. Regarding soil corrosion, the soils that are the most corrosive have:
A) High acidity
B) High moisture (electrolyte) content
C) High moisture content and high dissolved salt concentrations
D) High moisture content, high dissolved salt concentrations and high acidity
ANS: D … Ref: 4.3.9.3.d  Soil Corrosion (Critical Factors)
58f. Soil-to-air interface areas are often much more susceptible to corrosion than the rest of
the structure due to the availability of:
A) Moisture and oxygen

B) Moisture with electrolytes
C) Moisture and dissolved salts
D) Moisture and dissolved salts and acids
ANS: A … Ref: 4.3.9.3.e  Soil Corrosion (Critical Factors)
58g. Soil corrosion rates:
A) Decrease with increasing metal temps

B) Increase with decreasing metal temps
C) Increase with increasing metal temps
D) Are not affected by the metal temps
ANS: C … Ref: 4.3.9.3.f  Soil Corrosion (Critical Factors)
58h. Soil corrosion of carbon steel can be minimized through the use of:
A) Corrosion resistant coatings and CP

B) Special backfill, coatings and CP
C) Special backfill & coatings
D) Effective drainage and CP
ANS: B … Ref: 4.3.9.6  Soil Corrosion (Prevention/Mitigation)

93

58i. The most effective protection against Soil corrosion is:
A) Combination of corrosion resistant coatings and CP

B) Special backfill and Cathodic Protection system
C) Homogenous backfill and sound coatings
D) Sound coating system
ANS: A … Ref: 4.3.9.6  Soil Corrosion (Prevention/Mitigation)
58j. The most common method used for monitoring UG structures for soil corrosion is:
A) Visual evaluation after excavation

B) Measuring structure to soil potentials
C) Measuring soil corrosivity using the IR drop method
D) Measuring soil resistivity using NACE RP 0169 methods
ANS: B … Ref: 4.3.9.7.a  Soil Corrosion (Inspection and Monitoring)
58k. Regarding soil corrosion, CP should be performed and monitored in accordance with:
A) NACE RP0169
B) NACE RP0274
C) Owner user Standard
D) API 652 & NACE RP0274
ANS: A … Ref: 4.3.9.7.a  Soil Corrosion (Inspection and Monitoring)
Soil Corrosion! You will get 1 of 11 on API 571 exam, Wiggum! I can get dirty!
Yeah, Wiggie … Let’s go!!! I got a new rap video called DOWN & DIRTY, BABY!!!
I love doing buried pipeline jobs because I always know SCHEDULE comes first & we just
throw anything back into the trench! Who is crazy enough to make a sweet sand pad above
& below & around a buried pipeline? You just bulldoze the rocks and stones and sticks in
there when Inspectors aren’t watching! And we backfill during the weekends no problem!!!
We always can expect leaks and failures and EXTRA WORK $$$ Fixing up our bad jobs!
Babu! … Exxon makes Contractors video backfilling now! Word has gotten out, and
it will be a Project Requirement globally soon! Now get out of here before I lose my temper
& get my inspection hammer out and give you a “DIRT NAP RAP SLEEPY TIME OUT”
He, he, he, he, he, he, he, he! Oh boy, Cletus! You really got down and dirty on Babu!
End of DM # 58  How did you do on the 11 Soil Corr. Qs?

94
DM # 59 … METAL DUSTING
59a. Metal Dusting primarily affects all of the following in a carburizing environment
EXCEPT:
A) Fired Heater Tubes

B) Thermowells
C) Instrument Connections
D) Furnace Components
Answer = C … See Paragraph 4.4.5.4.a  Affected Units or Equipment

95
DM # 60 … STRAIN AGING
60a. Carbon steels and C-0.5 Mo Low alloy steels manufactured by Bessemer or open
hearth process are more likely than new steels to be susceptible to:
A) Strain Aging B) 885°F Embrittlement
C) Sigma Phase Embrittlement D) Temper Embrittlement
Answer = A … See Par 4.2.4.1 & 4.2.4.3.b/c (Description of Damage & Critical Factors)
60b. Best prevention method against effects of strain aging when making weld repairs is:
A) It is too late once damage is present B) Maintain preheat & interpass temps
C) PWHT (and also BHT) D) PMI & BHT
Answer = C … See Paragraph 4.2.4.6.c below (Prevention) & Affected Units
4.2.4.6 Prevention / Mitigation
a) Strain aging is not an issue for newer steels that contain low levels of interstitial impurity
elements and sufficient aluminum (>0.015 wt%) to fully deoxidize the steel.
b) For older equipment, extra care should be taken to avoid the potentially damaging effects of
strain aging by avoiding stressing or pressurizing equipment until the metal temperature reaches
an acceptable level where the risk of brittle fracture is low. Refer to curve “A” in UCS 66 of the
ASME Code Section VIII, Division I for pressurization temperatures of vessels susceptible to
strain aging effects.
c) Applying PWHT to weld repairs of susceptible materials will eliminate the effects of
strain aging. Where PWHT is not possible, buttering should be considered to minimize
welding on old material under restraint.

96
DM # 61 … SULFATE SCC
61a. Which statement is false regarding Sulfate SCC?
A) Copper alloy (admiralty brass) is highly susceptible & copper nickel alloys are more resistant
B) Surface initiated cracks (environmental cracks) of copper alloys in sulfate solutions result
C) Most commonly found in heat exchanger tubes and primarily in cooling water services
D) Damage in copper alloys under stress and in sulfate solutions occurs very quickly
Ans = D … See Para 4.5.8.1/2  Sulfate SCC … D of D & Aff Matls  Damage over years
61b. Which statement is false regarding Sulfate SCC critical factors?
A) Process environment must contain sulfates (part of process or formed due to reaction with
other chemical species)
B) Cracking usually occurs over many years, sometimes taking 10 to 15 yrs to cause tube leaks
C) Cracking occurs under combination of stress & in presence of sulfate chemical compounds
D) A water phase with ammonia accompanying the sulfate solution must be present
Ans = D … See Par 4.5.8.3.a/b/c/d  Sulfate SCC … Crit Factors  D = CF for Amm SCC
61c. Which Units & Equipment is Sulfate SCC most often associated with?
A) Tubes in HE bundles in overhead distillation systems such as those found in a Crude Unit
B) Tubes in HE bundles in a variety of Amine systems including overhead condensers
C) Tubes in HE bundles in Hydrogen Reforming Units (waste heat exchangers)
D) FCC overhead systems Tubes in HE bundles in FCC overhead systems
Ans = A … See Par 4.5.8.4  Sulfate SCC … Affected Equip & Units
61d. Which statement is FALSE regarding the appearance of Sulfate SCC?
A) Metallography shows cracks have a branched, transgranular appearance

B) Exchanger tubes show single or highly branched cracks on the surface
C) Tube failures usually result in slow leaks as opposed to tube rupture
D) Cracking is visually difficult to differentiate from Chloride SCC
Ans = D … See Par 4.5.8.5.a.b.c  Sulfate SCC … AppearanceLooks like Ammonia SCC
61e. How can Sulfate SCC be found (Insp/Monitoring method) in early stages of damage
when shallow cracks can be found?
A) By metallography B) By Flux leakage methods

C) By visual examination only D) Physical bending of sample tubes
Ans = D … See Par 4.5.8.5.a.b.c  Sulfate SCC … AppearanceLooks like Ammonia SCC

97
DM # 62 … PHOSPHORIC ACID CORROSION

62a. Most Phosphoric Acid Corrosion probably occurs during:
A) Polymerization unit operation with high levels of contaminants

B) Polymerization unit operation where flow velocities are high
C) Water washing operations during Unit Shutdowns
D) Water washing operations during Unit Operations
Ans = C … See Para 5.1.1.9.3.e  Phosphoric acid corrosion … Critical Factors
62a. Phosphoric Acid Corrosion is usually found in piping and equipment in:
A) Polymerization units where water mixes with catalyst

B) Polymerization units where flow velocity is high
C) Crude Unit overhead systems along with HCL
Ans = A … See Para 5.1.1.9.4.a  Phosphoric acid corrosion … Affected Units or Equip
62a. Corrosion in systems containing phosphoric acid is usually found in areas where:
A) Temperatures fall below the dew point

B) Flow velocity is low
C) Flow velocity is high
D) Sulfur contamination exists
Ans = B … See Para 5.1.1.9.4.b  Phosphoric acid corrosion … Affected Units or Equip

98
DM # 63 … PHENOL (Carbolic Acid) CORROSION

63a. Another name for Phenol Corrosion is:
A) Carbonic acid corrosion B) Carbolic acid corrosion

C) Carbon dioxide corrosion D) None of these are correct
Answer = B … 5.1.1.8 Phenol (Carbolic Acid) Corrosion  Description of Damage
63b. Which selection below lists all Critical factors for Phenol Corrosion?
A) Temperature, water content, alloy chemistry and velocity

B) Temperature, CO2 content, alloy chemistry and velocity
C) Temperature, alloy chemistry and velocity
Answer = A … 5.1.1.8.3.a Phenol (Carbolic Acid) Corrosion  Critical Factors
63c. The most useful NDT for Phenol (Carbolic Acid) Corrosion is:
A) UT B) RT
C) ER Corrosion Probes D) Both UT & RT
Answer = D … See Para. 5.1.1.8.7.a (Inspection & Monitoring) … ER (Elect Resistance)
5.1.1.8.3 Critical Factors

a) Temperature, water content, alloy chemistry and velocity are the critical factors.
b) Corrosion is usually minimal in the treating section when temps are below 250°F (121°C).
c) Corrosion can occur in the recovery section where spent phenol is separated by vaporization.
d) Sulfur & organic acids may lead to naphthenic acid attack & sulfidation in hot extract circuits.
e) Carbon steel & 304/304L SS corrode rapidly in phenol service above 450°F (232°C).
g) High velocities may promote localized corrosion.
Carbolic Acid corrosion … 5.1.1.8.4 Affected Units or

Equipment:
Phenol extraction facilities in lubes plant.
5.1.1.8.5 Appearance or Morphology of Damage
a) Corrosion will be in the form of general or localized corrosion of carbon steel.
b) Localized loss in thickness due to erosion-corrosion may occur.

99
DM # 64 … ETHANOL SCC
64a. Which of these factors increase the propensity (tendency) for Ethanol SCC?
A) Dissolved oxygen and the presence of variable stresses (such as cyclical stresses)
B) Carbon Dioxide and the presence of variable stresses (such as cyclical stresses)
C) Water soluble organic salts and cyclical stresses (thermal, mechanical)
Answer = A … Ref: Para 4.5.7.1 … Ethanol SCC  Description of Damage
64b. The likelihood of Ethanol SCC can be reduced by:
A) PWHT to above 1200°F (649°C)

B) Thick film coatings application
C) PWHT or coatings application
Answer = C … Ref: Para 4.5.7.1 … Ethanol SCC  Prevention

100
DM # 65 … OXYGEN-ENHANCED IGNITION & COMB

65a. What statement is False about Gaseous Oxygen-Enhanced Ignition & Combustion?
A) In some environments, spontaneous ignition or combustion of metallic components can occur

B) Many metals are flammable in O2 and enriched air (> 25% O2) service even at low pressures
C) Once ignited, metals burn more vigorously with higher O2 purity, pressure and temperature
D) The spontaneous ignition or combustion of nonmetallic components cannot result in fires
Answer = D … See Para. 4.2.20.1 … O2 Enhanced Ignition & Comb  Descript of Damage
65b. What statement is False about materials affected by Gaseous Oxygen-Enhanced

Ignition & Combustion?
A) CS is flammable in low pressure (> 15 psig) O2 service but safe at high pressure O2 service
B) Austenitic SS has better resistance to low pressure O2 & is difficult to ignite below 200 psig
C) Copper (>55%) and nickel (>50%) alloys are fire resistant and considered non-flammable
D) Titanium alloys are widely used in O2 service because they have low ignition energies
Answer = D … See Para. 4.2.20.2 … O2 Enhanced Ignition & Comb  Affected Materials
65c. Combustion & ignition in O2 services depend upon all these critical factors EXCEPT:
A) System pressure, oxygen content of the stream and line velocity
B) Component thickness, design and piping configuration
C) Cleanliness and temperature
D) pH and contaminants
Answer = D … See Para. 4.2.20.3.a … O2 Enhanced Ignition & Comb  Critical Factors
65d. Regarding Oxygen-enhanced Ignition & combustion, the primary concern for high
velocity oxygen flow conditions is:
A) Entrainment of particulate matter and subsequent impingement on a surface (esp. pipe bends)
B) Component piping configuration and cleanliness
C) Temperature and contaminants
D) None of these
Answer = A … See Para. 4.2.20.3.b … O2 Enhanced Ignition & Comb  Critical Factors
65e. What statement is False about Insp & Monitoring for Gaseous Oxygen-Enhanced
Ignition & Combustion?
A) Tell-tale signs of a minor fire are signs of malfunctioning valves or other components
B) Black lights can be used to check for hydrocarbon contamination that can cause fires
C) Tell-tale signs of a minor fire are the visible signs of external heat damage
D) Black lights can be used to check for internal heat damage
Answer = D … See Para. 4.2.20.7.b/c … O2 Enhanced Ign & Comb  Insp & Monitoring

101
DM # 66 … Aqueous Organic Acid Corrosion  5 Q&A

66a. Compounds in crude oils that decompose in crude furnaces to form low molecular
weight acids (naturally occurring) that condense in Distillation Tower Overhead systems
are indicative of:
A) MIC B) HCL Corrosion

C) Aqueous Organic Acid Corrosion D) Ammonium Chloride Corrosion
Answer = C … See Para. 5.1.1.12.1 … Organic Acid Corr  Description of Damage
66b. Aqueous Organic Acid corrosion is a function of type & quantity of organic acids and:
A) Metal temperature, fluid velocity, system pH, and the presence of other acids
B) Metal temperature, fluid velocity, system pH, and the presence of chlorides
C) Metal temperature, fluid velocity, system pH, and presence of HCL Acid
D) None of these
Answer = A … See Para. 5.1.1.12.3.a … Organic Acid Corr  Critical Factors
66c. The most severe acids causing damage known as Aqueous Organic Acid corrosion are:
A) Formic acid, acetic acid, propionic acid, and butyric acid

B) Propionic acid and Butyric acid only
C) Formic acid and acetic acid only
D) None of these
Answer = C … See Para. 5.1.1.12.3.b/c & Table 5.3 … Organic Acid Corr  Crit Factors
66d. Aqueous Organic Acid corrosion affects all CS piping and process equipment in:
A) Crude tower, vacuum tower and coker fractionator overhead systems in HEs, towers & drums
B) Crude tower and vacuum tower and FCC Unit overhead systems in HEs, towers & drums
C) Crude tower and vacuum tower overhead systems in towers & drums
D) None of these
Answer = A … See Para. 5.1.1.12.4.a … Organic Acid Corr  Affected Units/Equipment
66e. Aqueous Organic Acid corrosion is difficult to distinguish from other acid damage in
Overhead systems and is sometimes mistaken for:
A) MIC damage or Dealloying
B) HCL corrosion or Carbonic Acid corrosion
C) Ammonium Chloride Corrosion or Ammonium Bisulfide Corrosion
D) None of these
Answer = B … See Para. 5.1.1.12.5.a … Organic Acid Corr  Appearance

102
REVIEW SA SANITARY CODE FOR

DISINFECTION PRACTICES ON
TANKS & PIPING
Now it’s time to take a Practice Exam!

See Practice Exam Folder & Take the
300+ Question API 571 Practice Exam
Next Section … SABP’s
& SAEP-325 (Insp Reqmts)
Required Reading Assignment
Compare SAEP-325 requirements &
API 571 recommendations for Damage
mechanism Inspection Practices
END OF 2014 API 571 SG Q&A

103
API 570 EXAM (16 DMS OF API 571 & API 574 Points)  API 570, PARA. 5.4.1.3
1. Cause for cracking on a ¾” NPS CS high point vent on a steam relief line is likely due to:
A) Mechanical Fatigue B) Vibration-induced fatigue

C) Stress Corrosion Cracking D) Original fabrication weld defect
Answer = B … See Para. 4.2.17.4/5/6 (Affected Units/Appearance/Prevention)

2. The most important factor in determining component resistance to Mechanical Fatigue is:
A) Design B) Operation C) Material D) Time (Number of cycles)
Answer = A … See Para. 4.2.16.3.a (Critical factors)

3. The common method used to monitor boiler water for condensate corrosion is:
A) Operational Temp Range Analysis B) Treatment Chemical (Scavenger) Analysis
C) Water Analysis D) pH Analysis
Answer = C … See Para. 4.3.5.7 (Inspection & Monitoring)

4. Boiler water condensate corrosion pitting caused by oxygen is particularly aggressive:
A) In stagnant flow areas B) In high velocity (turbulent) areas
C) When water temps rise rapidly D) When water temps fall below design
Answer = C … See Para. 4.3.5.5.a (Appearance or Morphology)

5. Which materials are highly (most) susceptible to Chloride Stress Corrosion Cracking?
A) Martensitic SS B) Duplex SS C) 300 Series SS D) Nickel based alloys
Answer = C … See Para. 4.5.1.2 (Affected Materials, Critical Factors, Description of Dam)
6. Critical factors for Chloride Stress Corrosion Cracking include all of the following EXCEPT:
A) Chloride content B) pH & temperature C) Alloy composition D) Stress & presence of CO²
Answer = D … See Para. 4.5.1.3.a (Critical Factors) …  stress & presence of oxygen
7. Sulfidation damage is accelerated by the presence of:
A) Hydrogen B) Sulfur C) Salts D) Corrosive Water
Answer = A … See Paragraph 4.4.2.1 (Description of Damage)

8. Prevention of CUI is best achieved by:
A) Carefully planned periodic inspections B) Using quality coatings
C) Careful visual exam of insulation covers D) None of these are correct
Answer = B … See Paragraph 4.3.3.7.a (Prevention  mentioned in Insp & Monitor)

104
9. Critical Environmental Factors for CUI can include all of the following EXCEPT:
A) Insulation system design & type B) Humidity & Rainfall
C) Chlorides from Marine Environment D) Industrial pollution (SO², etc)
Answer = A … See Paragraph 4.3.3.3.a (Critical Factors)
10. Most cases of Brittle Fracture occur only at:
A) Temperatures above Charpy Impact transition temperatures
B) Charpy Impact temperatures have no relationship to Brittle Fracture occurrences
C) Temperatures below ambient and only in thick sections
D) Temperatures below Charpy Impact transition temperatures
Answer = D … See Paragraph 4.2.7.3.e below  Critical Factors
11. Due to HTHA considerations, what steel alloy is no longer recommended for new
construction in hot hydrogen services?
A) Mn ½ Mo B) 1¼ Cr ½ Mo C) 1Cr ½ Mo D) C – 0.5 Mo
Answer = D … See Paragraph 5.1.3.1.6.c&d below  Prevention/Mitigation
12. Metal loss that is the result of impact or abrasion with contributing corrosion is referred to as:
A) Pitting B) Erosion C) Corrosion D) Erosion/Corrosion
Answer = D … See Paragraph 4.2.14.a  Description of Damage
13. HTHA damage is usually detected (determined) by which of the following methods?
A) UT velocity ratio & backscatter B) MT or PT C) WFMT D) RT
Answer = A … See Paragraph 5.1.3.1.7.b  Inspection & Monitoring
14. HTHA results from exposure to hydrogen at elevated temperatures and pressures. Hydrogen
reacts with carbides in steel to form this gas that cannot diffuse through the steel.
A) Hydrogen B) Ethane C) Methane D) Pentane
Answer = C … See Paragraph 4.4.1.7.c  Description of Damage
15. Severe internal grooving with deep pitting was found at the bottom of a 4-inch CS elbow in a
steam condensate system. This damage was most likely caused by:
A) Erosion/Corrosion B) Chloride Corrosion
C) Ammonium Bisulfide Corrosion D) CO² Corrosion
Answer = D … See Paragraph 4.3.6.5.b  Appearance or Morphology of Damage
16. Steam actuated soot blowers may cause this damage mechanism if the first steam exiting the
soot blower nozzle contains condensate. What is the damage mechanism?
A) CO² Corrosion B) Erosion/Corrosion C) Condensate Corrosion D) Thermal Fatigue
Answer = D … See Paragraph 4..2.9.4.e  Affected Units or Equipment

105
17. The best way to prevent Thermal Fatigue during Operational Start-up & Shut Down is:
A) Use good design to eliminate stress B) Control rates of heating & cooling
C) Monitor thermal expansion D) None of these are correct
Answer = B … See Paragraph 4.2.9.3.c  Critical Factors
18. CUI becomes more severe at this metal temperature range (where water is less likely to
vaporize and insulation stays wet longer):
A) Between 212F (100C) & 250F (121C) B) Between Ambient & 212F (100C)
C) Between 212F (100C) & above (unlimited) D) Between 212F (100C) & 350F (177C)
Answer = D … See Paragraph 4.3.3.3.d  Critical Factors
19. Sulfidation of iron-based alloys usually begins at metal temperatures above:
A) 350°F (177°C) B) 500°F (260°C) C) 700°F (370°C) D) 800 ºF (425ºC)
Answer = B … See Paragraph 4.4.2.3.c  Critical Factors
20. What damage mechanism is best defined as the sudden rapid fracture under stress (residual or
applied) where the material exhibits little or no evidence of ductility or plastic deformation?
A) 885°F (475°C) Embrittlement B) Temper Embrittlement
C) Brittle Fracture D) Sigma Phase Embrittlement
Answer: C … API 571 … Para. 4.2.7.1 … Brittle Fracture Question
21. Regarding brittle fracture, when the critical combination of three factors is reached, brittle
fracture can occur. Select the item below that is NOT a critical factor regarding brittle fracture:
A) Material fracture toughness (resistance to crack like flaws) as measured in Charpy impact test
B) Material tensile strength (resistance to crack like flaws) as measured in a tensile test
C) Size, shape and stress concentration effect of a flaw
D) Amount of residual and applied stresses on the flaw
Answer: B … API 571 … Para. 4.2.7.3 … Brittle Fracture Question
22. Regarding brittle fracture failures, Cracking found by the Inspector will typically show
evidence of:
A) Straight, non-branching cracks largely without evidence of any associated plastic deformation
B) Branching cracks having evidence of a shear lip or localized necking around the cracks
C) Both straight & multi-facet cracks with evidence of a shear lip or localized necking at cracks
Answer: A … API 571 … Para. 4.2.7.5.a … Brittle Fracture Question
23. The accelerated mechanical removal of surface material as a result of relative movement
between, or impact from solids, liquids, vapor or any combination thereof is known as:
A) Erosion B) Erosion-Corrosion C) Corrosion D) None of these
Answer: A … API 571, Para. 4.2.14.1.a – Erosion/Erosion-Corrosion Question
106
24. Pure erosion is very rare and is sometimes referred to as:
A) Abrasive wear B) Undercutting C) Tiger striping D) None of these
Answer: A … API 571, Para. 4.2.14.3 – Erosion/Erosion-Corrosion Question
25. Critical factors related to Mechanical Fatigue and fatigue resistance include:
A) Geometry of the component

B) Stress levels & number of cycles
C) Material properties such as strength, hardness, and microstructure
D) All of these are correct
Answer: D … API 571, Para. 4.2.16.3 – Mechanical Fatigue Question
26. Regarding the appearance or morphology of Mechanical Fatigue, the signature mark of
fatigue failure will typically appear as:
A) Single clam shell fingerprint with vertical straight lines directly below the crack initiation site
B) Single clam shell fingerprint with rings called beach marks coming from a crack initiation site
C) Concentric lines throughout the entire cross-sectional area
Answer: B … API 571, Para. 4.2.16.5.a & Figures 4-30/31/32/33 – Mechanical Fatigue Question
27. A mechanical form of degradation in which cracks are produced as the result of dynamic
loading due to vibration, water hammer, slugging, or unstable fluid flow is known as:
A) Vibration-Induced Fatigue
B) Thermal Fatigue
C) Mechanical Fatigue
Answer: A … API 571, Para. 4.2.17.1 – Vibration-Induced Fatigue Question
28. Inspection & Monitoring strategies for Vibration-Induced Fatigue should include:
A) Checks for visible signs and evidence of vibration, pipe movement or water hammer. Note
that damage to insulation jackets may indicate excess vibration & this can result in wet insulation
B) Checks for the audible sounds of vibration emanating from piping components such as control
valves and fittings. Also, measure pipe vibrations using special monitoring equipment.
C) Conduct visual inspection during transient conditions (startup, shutdowns, upsets, etc.) for
intermittent vibrating conditions.
D) Use surface NDE methods (PT, MT), & check pipe supports & spring hangers regularly.
E) All of the above
Answer: E … API 571, Para. 4.2.17.7.a/b/c/d/e/f/g – Vibration-Induced Fatigue Question
Note: No API exam questions will have answers that are “ALL OF THE ABOVE”

107
29. Uniform or Localized Loss of Thickness Mechanisms include all of these EXCEPT:
A) Galvanic Corrosion, Atmospheric Corrosion, Corrosion under Insulation (CUI)
B) Cooling Water Corrosion, Boiler Water Condensate Corrosion, CO2 Corrosion
C) Flue-Gas Dew-Point Corrosion, Microbiologically Induced Corrosion (MIC), Soil Corrosion
D) Caustic Corrosion, Dealloying, Graphitic Corrosion
E) Oxidation, Sulfidation, Carburization, & Metal Dusting
Answer: E … API 571, Index for Section 4.0 … E Uniform or Localized Loss of Thickness
30. Environment – Assisted Cracking Mechanisms include:
A) Chloride Stress Corrosion Cracking (Cl-SCC), Ammonia Stress Corrosion Cracking
B) Corrosion Fatigue, Caustic Stress Corrosion Cracking (Caustic Embrittlement)
C) Liquid Metal Embrittlement (LME), Hydrogen Embrittlement (HE)
D) All of these are correct
Answer: D … API 571, Index for Section 4.0 – D Includes all 6 mechanisms
31. A form of corrosion that occurs from moisture associated with atmospheric conditions.
Marine environments and moist polluted industrial environments with airborne contaminants are
the most severe, and Dry rural environments cause very little corrosion. This mechanism is:
A) Atmospheric Corr B) Galvanic Corrosion C) Soil Corrosion D) Cooling Water Corrosion
Answer: A … API 571, Para. 4.3.2.1 – Atmospheric Corrosion Question
32. Atmospheric Corrosion rates vary greatly due to a variety of factors (see question above).
Corrosion rates increase with the temperature up to about 250°F (121°C). At temperatures above
250°F (121°C), the equipment surfaces are:
A) Susceptible to conditions that cause increased corrosion rates
B) Susceptible to conditions that cause decreased corrosion rates
C) Usually too dry for corrosion to occur
D) Usually too dry for corrosion to occur, except under insulation (that can remain wetted)
Answer: D … API 571, Para. 4.3.2.3.f – Atmospheric Corrosion Question
33. Insulating materials often “hold moisture” that creates corrosion. The ability of insulation to
draw and hold water or moisture is known as:
A) Wicking B) Saturation C) Wetting D) None of these are correct
Answer: A … API 571, Para. 4.3.3.3.f – Corrosion under Insulation Question
34. Location of equipment is a concern for CUI. Areas of high moisture that require close
surveillance of CUI include which of the following:
A) Areas down-wind from cooling towers, near steam vents
B) Areas with deluge systems and areas near supplemental cooling with water spray
C) Areas where acid vapors are present
D) All of the above are correct
Answer: D … API 571, Para. 4.3.3.5.a – Corrosion under Insulation Question
108
35. Corrosion in boiler feedwater and condensate return systems is usually the result of:
A) Dissolved gases, oxygen & CO2 B) Free gases, oxygen and SO2
C) Dissolved gases and oxygen only D) None of these are correct
Answer: A … API 571, Para. 4.3.5.3.a – Boiler Water Condensate Corrosion Question
36. When Sulfur & chlorine species in fuel will form sulfur dioxide, sulfur trioxide & hydrogen
chloride within the combustion products, and low enough temperatures exist, then gases & water
vapor in the flue gas will “condense” to form sulfurous acid, sulfuric acid & hydrochloric acid
which can lead to this type of severe corrosion which is known as:
A) CO2 Corrosion
B) Flue-Gas Dew Point Corrosion
C) Cooling Water Corrosion
Answer: B … API 571, Para. 4.3.7.1 – Flue-Gas Dew Point Corrosion Question
37. A form of corrosion caused by living organisms such as bacteria, algae or fungi that is often
associated with the presence of tubercles or slimy organic substances is known as:
A) MIC B) Soil Corrosion
C) Atmospheric Corrosion D) None of these
Answer: A … API 571, Para. 4.3.8.1 – Microbiologically Induced Corrosion (MIC) Question
38. MIC is usually found in aqueous environments or services where water is:
A) Always or sometimes present and especially where stagnant or low-flow conditions allow
and/or promote the growth of microorganisms
B) Adequately treated with biocides, ozone, UV light or other means.
C) Subject to high velocities
Answer: A … API 571, Para. 4.3.8.3.a – Microbiologically Induced Corrosion (MIC) Question
39. Inspection and Monitoring for MIC is done by:
A) In cooling water systems, effectiveness of treatment is monitored by measuring biocide
residual, microbe counts and visual appearance.
B) Special probes designed to monitor for evidence of fouling that may precede MIC damage
C) Increase in loss of duty of a heat exchanger may indicate fouling & potential MIC damage
D) All of the above are correct, and also foul smelling water is often a sign of trouble with MIC
Answer: D … API 571, Para. 4.3.8.7.a/b/c/d – MIC Question
40. The deterioration of metals exposed to soils is referred to as:
A) MIC B) Soil Corrosion
C) Atmospheric Corrosion D) None of these are correct
Answer: B … API 571, Para. 4.3.9.1 – Soil Corrosion Question

109
41. Soil corrosion affects:
A) Carbon steel, cast iron, & ductile irons
B) CS, cast & ductile irons, low alloy steels
C) CS, cast & ductile irons, low alloy & SS
Answer: A … API 571, Para. 4.3.9.2 – Soil Corrosion Question
42. Which of the following critical factors below apply to Soil corrosion?
A) Operating temperature, moisture and oxygen availability
B) Soil resistivity (condition & characteristics), soil type (water drainage), & soil homogeneity
C) Cathodic protection, stray current drainage, coating type, age, and condition.
D) All of the above are correct
Answer: D … API 571, Para. 4.3.9.3.a – Soil Corrosion Question
43. Regarding soil corrosion, Soil resistivity is frequently used to estimate soil corrosivity,
mainly because it is easy to measure. Soil resistivity is related to:
A) Soil moisture content
B) Amount of dissolved electrolytes in soil’s water
C) Both A & B are correct
Answer: C … API 571, Para. 4.3.9.3.c – Soil Corrosion Question
44. Soils with high moisture content/dissolved salt concentrations/high acidity are usually:
A) Most corrosive B) Least corrosive C) No difference exists D) None of these
Answer: A … API 571, Para. 4.3.9.3.d – Soil Corrosion Question
45. Soil-to-air interface areas are often much more susceptible to other areas of corrosion
in the rest of the structure because of:
A) Moisture at the air to soil interface B) Oxygen (from air) at air to soil interface
C) Both A & B are correct D) None of these are correct
Answer: C … API 571, Para. 4.3.9.3.e – Soil Corrosion Question
API 574 Section 7.4.7 (Erosion/Erosion Corrosion)
46. API 574 Para. 7.4.7 & 7.4.8: This type of corrosion __________________ occurs at high-
velocity and high-turbulence areas. Examples of places to inspect include (all of these EXCEPT):
A) Downstream of control valves where flashing or cavitation is occurring
B) Downstream of orifices and pump discharges
C) At any point of flow direction change, such as the outside radii of elbows
D) In any straight run of piping at the lowest points

110
47. Examples of places to inspect for erosion/erosion corrosion incl. all these EXCEPT:
A) Downstream of control valves where flashing or cavitation is occurring
B) Downstream of orifices and pump discharges
C) At any point of flow direction change, such as the outside radii of elbows
D) In any straight run of piping at the lowest points
48. Areas suspected to have localized erosion/erosion corrosion should be inspected using
appropriate NDE methods that will yield thickness data over a wide area, such as:
A) RT only B) UT only
C) UT scanning and profile RT D) None of these
API 574 Section 7.4.8 (Environmental Cracking)
49. Piping system construction materials are normally selected to resist various forms of
SCC. Piping systems can be susceptible to environmental cracking from upset process
conditions, CUI, unanticipated condensation, or exposure to wet hydrogen sulfide or
carbonates.
Examples of this damage mechanism resulting from moisture & chlorides under insulation,
under deposits, under gaskets, or in crevices is called:
A) Chloride SCC of austenitic SS B) Polythionic acid SCC of austenitic SS
C) Caustic SCC D) None of these
50. Caustic SCC is sometimes known as  Caustic Embrittlement
Score yourself on the 50 questions … How did you do? Retest until you score 100%
IF YOU MISSED ANY  STUDY THAT SECTION AGAIN CAREFULLY
Environmental Cracking
51. Which of these damage mechanisms results from moisture and salts under insulation,
under deposits, under gaskets, or in crevices?
A) Chloride SCC of austenitic SS B) Polythionic acid SCC of austenitic SS

C) Caustic SCC D) None of these
Answer: A … 574, Para. 7.4.8.1.a  Must know 574 Environmental Cracking points
52. The two forms of CUI are:
A) General corrosion and localized corrosion of carbon, low alloy and SS

B) General corrosion of carbon steels and chloride SCC of austenitic stainless steels
C) Localized corrosion of carbon steels and chloride SCC of austenitic stainless steels
D) Both general and localized corrosion of carbon steels and chloride SCC of austenitic SS
Answer: C … 574, Para. 7.4.4 … Know the relationship between CUI & Chloride SCC
111
571 Exam ADD ONS  HTHA & CREEP

10e. Which of these mechanisms is difficult to distinguish from HTHA in the early stages?
A) Wet H2S Damage (Blistering & HIC) B) Hi-Temp H2/H2S Corrosion
C) Sulfidation D) Creep
Ans: D … 571 Par. 5.1.3.1.5 …HTHA in early stages is difficult to distinguish from CREEP
3i. Which of these Pressure Vessel materials are particularly prone to low creep ductility?
A) High tensile strength CS B) 1 Cr – 0.5 Mo & 1.25 Cr – 0.5 Mo

C) 2-1/4Cr-1Mo – Quenched & Tempered D) Type 304 & 304H Austenitic Stainless Steel
Answer: B … 571 Par. 4.2.8.6.b/4.2.8.7.b…Creep  Prev/Mitigation & Insp & Monitoring
24c. Carburization in carbon and low alloy steels occurs when carbon reacts to form:
A) A single phase microstructure where all of the pearlite has been removed
B) A single phase microstructure where all of the ferrite has been removed
C) A hard, brittle structure at surface that may crack or spall upon cooling
Answer: C … Ref: 4.4.3.3.d  Carburization Above 1100°F (593°C)… Critical Factors
24d. 300 Series SS are more resistant than CS & low alloy steels to Carburization due to:
A) The amount of ferrite that exists in the microstructure

B) The amount of martensite that exists in the microstructure
C) The higher chromium and nickel content in the microstructure
Answer: C … Ref: 4.4.3.3.e  Carburization Above 1100°F (593°C)… Critical Factors
24e. Carburization can result in any of the following deficiencies EXCEPT:
A) Loss of weldability
B) Loss of Creep Resistance
C) Loss of high temperature creep ductility
D) Loss of ambient temp mechanical properties (specifically toughness/ductility)
Answer: B … Ref: 4.4.3.3.f  Carburization  Loss of Corr Resistance … Critical Factors

112
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1

API 571 Introduction

Saudi Aramco: Company General Use

Welcome to API 571 Course & Self Study

 Critical Factors  29 questions of 70 utilized this section (answer)  # 1 priority

WHEN YOU STUDY …

Additional important points!!!

API 571 COURSE & SELF STUDY GUIDE

A) Hydrogen B) Sulfur C) Salts D) Corrosive Water

Answer = A … See Paragraph 4.4.2.1 (Description of Damage)

A) Carbon steels B) Low alloy steels ≥ 7% Chrome

1c. Sulfidation of iron-based alloys usually begins at metal temperatures above:

A) 500°F (260°C) B) 700°F (370°C) C) 900°F (482°C) D) 1000°F (538°C)

Answer = A … See Paragraph 4.4.2.3.c (Critical Factors)

A) 3-5% B) 5-7% C) 7-9% D) 12%

1e. Which Curves are utilized to determine Sulfidation corrosion rates?

A) Couper-Gorman B) McConomy C) Nelson D) None of these

1f. Sulfidation occurs at high temps and is primarily caused by:

Answer: D … Ref: 4.4.2.3.f … Critical Factors

DM # 1 … SULFIDATION (12 Q&A)

Answer = C … See Paragraph 4.4.2.5.a below (Appearance)

Answer = B … See Paragraph 4.4.2.5.b below (Appearance)

Answer = A … See Paragraph 4.4.2.6 below (Prevention)

End of DM # 1  How did you do on 12 questions?

DM # 2 … WET H²S DAMAGE 20 Q&A

Answer = C … Ref: 5.1.2.3.1.a … Description of Damage (Wet H2S Damage  Blistering)

2d. Regarding wet H2S damage, SOHIC appears as:

DM # 2 … WET H²S DAMAGE 20 Q&A

2g. Wet H2S damage affects:

A) Carbon steels only

A) Environmental conditions (pH, H2S level, contaminants, temperature)

Answer = D … Ref: 5.1.2.3.3.a … Critical Factors (Wet H2S Damage)

A) Minimal at pH 10 and increases at higher and decreases at lower pH values

Answer: B … Ref: 5.1.2.3.3.b.i … Critical Factors (Wet H2S Damage  pH)

Answer: D … Ref: 5.1.2.3.3.b.3 … Critical Factors (Wet H2S Damage  Temperature)

DM # 2 … WET H²S DAMAGE 20 Q&A

Answer: D … Ref: 5.1.2.3.3.b.4 … Critical Factors (Wet H2S Damage  Hardness)

2n. Regarding Wet H2S Damage, PWHT is not useful for:

A) Carbonate SCC B) Sulfide stress cracking (SSC)

2o. Blistering, HIC, SOHIC and SSC damage can occur:

A) Anywhere in refinery in a wet H2S environment

Answer: A … Ref: 5.1.2.3.4.a … Affected Units (Wet H2S Dam)

Saudi Aramco: Company General Use

DM # 2 … WET H²S DAMAGE 20 Q&A

A) Blistering only B) Blistering & HIC damage

Answer: C … Ref: 5.1.2.3.4.c … Affected Units (Wet H2S Dam)

2s. Inspection for Wet H²S damage generally focuses on:

A) All internal welds B) Trays and down comers

Answer: C … Ref: 5.1.2.3.7.b … Inspection & Monitoring

Answer = D … See Paragraph 5.1.2.3.7.d/e  Inspection & Monitoring

End of DM # 2  How did you do on 20 questions?

Saudi Aramco: Company General Use

DM # 3 … CREEP/STRESS RUPTURE  12 Q&A

A) CS = 650°F (343°C), Low Alloy steel = 800°F (427°C), SS = 900°F (482°C)

Saudi Aramco: Company General Use

DM # 3 … CREEP/STRESS RUPTURE  12 Q&A

A) Temperatures below creep threshold limits for a given material

Answer: A … Ref: 4.2.8.3.d … Critical Factors (Creep)  Threshold Limit Fact

A) Indicates that a material has low creep ductility

Answer: A … Ref: 4.2.8.3.e/f … Critical Factors (Low Creep Ductility)

3g. Regarding Low Creep ductility, which statement is FALSE?

Saudi Aramco: Company General Use

DM # 3 … CREEP/STRESS RUPTURE  12 Q&A