CKRC API 510 WORKBOOK DEC 2013_______________________________

API-510 PRESSURE VESSEL INSPECTOR CERTIFICATION

EXAMINATION PREPARATION COURSE

Presented by CKRC Training Solutions cc

Module: 4
Subject: General - API RP 571, Damage Mechanisms Affecting Fixed
Equipment in the Refining Industry
(MKMXEPP]WMKRIHF]/IZMR6SFIVX1EPI]
 
    
Author    

Kevin Robert Maley     
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This courseware is based on the API 510 Body of Knowledge approved for
the API 510 Certification examination scheduled for 4 December 2013.
Unauthorized reproduction, distribution or incorporation of the material
contained in this workbook is a violation of copyright law.

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CKRC API 510 WORKBOOK DEC 2013_______________________________

Module Objective: The Inspector shall have a sound general knowledge of the applicable
extracts from API RP571.

RA: API RP571 - 1.1 Introduction, 1.2 Scope, 1.3 Organization and Use, 3.1 Terms, 3.2 Symbols
and Abbreviations, 4.1 General

Par.
3. - Definitions (included as a frame of reference only)
4.2.3 – Temper Embrittlement
4.2.7 – Brittle Fracture
4.2.9 – Thermal Fatigue
4.2.14 – Erosion/Erosion-Corrosion
4.2.16 – Mechanical Failure
4.3.2 – Atmospheric Corrosion
4.3.3 – Corrosion Under Insulation
4.3.4 – Cooling Water Corrosion
4.3.5 – Boiler Water Condensate Corrosion
4.3.10 – Caustic Corrosion
4.4.2 – Sulfidation
4.5.1 – Chloride Stress Corrosion Cracking (Cl-SCC)
4.5.2 – Corrosion Fatigue
4.5.3 – Caustic Stress Corrosion Cracking (Caustic Embrittlement)
5.1.2.3 – Wet H2S Damage (Blistering/HIC/SOHIC/SCC)
5.1.3.1 – High Temperature Hydrogen Attack (HTHA)

Read all sections thoroughly to understand the layout of information and general content.

Module 4 Test 1A

Number of questions: 43

Recommended Time limit: 107.5 min (Based on an average of 2.5 min per question)

Test comments:
Test should be attempted after completion of the RA.
Initial Attempt: Test should be attempted as a closed book test (no references required).
Recommended score: >90% (Note: Questions marked with ** are open book
questions and should not be counted towards the closed book scoring.)
Formal Attempt: Test should be attempted as an open book test (Show all supporting
References and calculations).
Recommended Score: >95%

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CKRC API 510 WORKBOOK DEC 2013_______________________________

1) Temper embrittlement can be identified by an upward shift in the ductile-to-brittle

transition temperature measured in a Charpy V-notch impact test.
a. True.
b. False.

2) What type of damage can be anticipated in a Pressure vessel constructed 2.25Cr-1Mo low
alloy steel and commissioned into service in a hydroprocessing unit reactor operating at a
temperature of 700°F?

3) Brittle fracture is the slow steady shearing under stress (residual or applied) where the
material exhibits little or no evidence of ductility or plastic deformation.
a. True.
b. False.

4) Are 300 series stainless steels which have not been subject to Embrittlement or
sensitization generally considered to be susceptible to brittle fracture?
a. Yes.
b. No.

5) Sudden rapid fracture under stress (residual or applied) where the material exhibits little
or no evidence of ductility or plastic deformation, best describes which of the following
general damage mechanisms?
a. Chloride Stress Corrosion Cracking.
b. Caustic Corrosion.
c. Brittle Fracture.
d. Mechanical Fatigue.

6) Which of the following steels are not generally considered to be affected by brittle
fracture (Note: for the purpose of this question special metallurgical and welding
phenomenon are excluded.)?
a. 300 series stainless steel.
b. 400 series stainless steel.
c. Carbon steel.
d. Low alloy steel.

7) Which of the following critical factors are required by themselves, or in combination to

exist for brittle fracture to occur?
a. The amount of residual and applied stresses on the flaw must exceed the
material’s ability to withstand failure.
b. The materials’ fracture toughness must be exceeded.
c. The size, shape and stress concentration effects of a flaw must be conducive to
cause brittle fracture.
d. All of the above.

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8) API RP 571 recommends that pressure vessels constructed of carbon and low alloy steel,
in accordance with ASME VIII – I, should be considered to have greater suspicion of
susceptibility to brittle failure, unless shown otherwise in the original design or service
records, if the vessel was fabricated to which of the following ASME VIII-I editions /
addenda and earlier?
a. December 1976.
b. December 1981.
c. December 1987.
d. June 2001.

9) When considering two pieces of material of the same specification, grade and thickness;
which of the following material characteristics are considered to have a significant
influence on toughness and resistance to brittle fracture?
a. Steel cleanliness (Material impurities).
b. Minor variations in chemical composition.
c. Material grain size.
d. Both a and c.

10) Which of the damage mechanisms listed below has the following appearance when
examined microscopically: the fracture surface will be composed largely of cleavage,
with limited Intergranular cracking and very little microvoid coalescence?
a. Caustic Stress Corrosion Cracking.
b. Brittle fracture.
c. Mechanical failure.
d. Microbiologically Induced Corrosion.

11) Thermal fatigue is the result of cyclic stresses caused by variations in temperature.
Damage is in the form of ___________.
a. Cracking.
b. Pitting.
c. Brittle fracture.

12) 1 ¼ CR ½ MO low alloy steels are not affected by thermal fatigue.

a. True.
b. False.

13) Crude and vacuum unit vessels exposed to naphthenic acids in some crude oils may
suffer severe erosion-corrosion metal loss; the severity depends on which of the
following factors?
a. Sulfur content.
b. Temperature.
c. Velocity.
d. Includes but is not limited to all of the above.

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14) Mechanical fatigue failure can arise from stresses from either mechanical loading or
thermal cycling and are typically well _________ the yield strength of the material
(Select the missing word).
a. below
b. above

15) Mechanical fatigue failure may arise from stresses due to either mechanical loading or
thermal cycling and are typically____________? (Select the option below the correctly
completes this sentence)
a. well above the impact properties of the material.
b. well below the tensile strength of the material.
c. well below the yield strength of the material.
d. well above the yield strength of the material.

16) Which of the following general damage mechanisms is characterized by a “clam shell”
type fingerprint that consists concentric rings emanating from single or multiple crack
initiation site when examined microscopically?
a. Chloride Stress Corrosion Cracking.
b. Brittle fracture.
c. Mechanical fatigue failure.
d. Sulfuric Acid Corrosion.

17) Mechanical fatigue is best defined by which of the following statements?

a. Electrochemical form of deterioration that occurs when a component is exposed
to cyclical stresses in a corrosive environment for an extended period, often
resulting in sudden, unexpected failure.
b. Mechanical form of deterioration that occurs when a component is exposed to
static hoop stresses for an extended period, often resulting in slow deformation
with predictable failure rate.
c. Mechanical form of deterioration that occurs when a component is exposed to
cyclical stresses for an extended period, often resulting in sudden, unexpected
failure.
d. Electrochemical form of deterioration that occurs when a component is exposed
to a corrosive environment for short periods at alternating hot and cold cycles,
often resulting in sudden, unexpected failure.

18) Which of the following areas indicated below are considered by API RP 571 to be a
common feature related to mechanical fatigue failure (Assume that the operating
conditions are conducive to this type of failure)?
a. Tooling marks.
b. Thread root notches.
c. Corrosion.
d. All of the above.

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19) Which of the following materials can be affected by atmospheric corrosion?

a. Carbon steel.
b. Low alloy steels.
c. Copper alloyed aluminum.
d. All of the above.

20) Select the appropriate atmospheric corrosion rate for the following locations (Open book
question only).
a. Inland locations exposed to a moderate amount of precipitation or humidity:
i. <1 mpy
ii. 1-3 mpy
iii. 5-10 mpy
iv. 20 mpy

b. Marine environments:
i. <1 mpy
ii. 1-3 mpy
iii. 5-10 mpy
iv. 20 mpy

c. Inland Industrial environments that contain sulfur compounds:

i. <1 mpy
ii. 1-3 mpy
iii. 5-10 mpy
iv. 20 mpy

21) Which of the following contaminants in the atmosphere or on an unprotected surface of

equipment may result in accelerated corrosion at the points of contamination?
a. Bird turds.
b. Fly ash from furnace stacks.
c. Chlorides from cooling tower drift.
d. All of the above may accelerate corrosion.

22) 300 Series SS is not affected by CUI.

a. True, because SS does not react with water.
b. True, because CUI only affects CS and low alloy steels.
c. False, CUI can be found in the form of Cl-SCC.
d. False, CUI can be found in the form of SCC if anhydrous ammonia is present.

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23) Which of the following statements are inconsistent with API RP571 for CUI?
a. In some localized cases, the corrosion can appear to be carbuncle type pitting
(usually found under a failed paint/coating system).
b. Tell-tale signs of insulation and paint/coating damage often accompany CUI.
c. CUI damage often appears as loose, flaky scale covering the corroded
component.
d. Older calcium silicate insulation material are known to improve the CUI
performance of 300 Series S/S.

24) Which of the following types of insulation materials will hold more water against the
surface of equipment when compared to the other options?
a. Closed-cell foamed glass insulation.
b. Mineral wool insulation.
c. Both Closed-cell foamed glass & Mineral wool materials are known to hold an
equal amount of water against the surface of equipment.

25) Which of the following statements does not describe a characteristic of CUI?
a. Insulating materials that hold moisture (wick) can be more of a problem than
insulating materials that are less hydroscopic.
b. Corrosion rates decrease with increasing metal temperature up to the point where
the water evaporates quickly at which point the effect CUI becomes negligible.
c. Corrosion becomes more severe at metal temperatures between the boiling point
212°F and 350°F.
d. Cyclic thermal operation or intermittent service can increase corrosion.

26) General or localized corrosion of carbon steels and other metals caused by dissolved
salts, gases, organic compounds or microbiological activity is a description of which type
of damage mechanism?

27) When it is proven that the oxygen scavenging treatment in condensate return systems are
working correctly, corrosion tends to be due to ____________. Note: This type corrosion
tends to appear as smooth grooving of the pipe wall. (Select the missing word)
a. Carbon dioxide.
b. Carbon monoxide.
c. Oxygen.
d. Hydrogen.

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28) Which of the following degradation mechanisms can best be described as Localized
corrosion due to the concentration of caustic or alkaline salts that usually occurs under
evaporative or high heat transfer conditions?
a. Atmospheric Corrosion.
b. Caustic Corrosion.
c. Microbiologically Induced corrosion.
d. Sulphuric acid corrosion.

29) Which of the following degradation mechanisms are sometimes found as localized
gouging along a waterline where corrosives concentrate?
a. Atmospheric Corrosion.
b. Caustic Corrosion.
c. Microbiologically Induced corrosion.
d. Sulphuric acid corrosion.

30) Caustic Corrosion is considered to have very high corrosion rates above which of the
following operating temperatures?
a. 100°F
b. 175°F
c. 200°F
d. 275°F

31) Which material forms sulphides at a lower temperature?

a. Copper base alloys.
b. 300 Series SS.
c. Nickel base alloys.

32) In accordance with the API RP 571; does the presence of dissolved oxygen increase the
propensity / tendency for cracking in 300 Series SS in chloride environments?
a. Yes.
b. No.

33) In the late 1980’s, many pressure vessel failures were recorded in the newspaper at
refining and petrochemical and fossil fueled utility industries due to cracks which
developed under the combined effects of cyclic loading and corrosion. Which of the
following vessel is linked to this cracking problem?
a. Reactors.
b. Deaerators.
c. Condensers.
d. Separators.

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CKRC API 510 WORKBOOK DEC 2013_______________________________

34) Caustic Embrittlement may occur in equipment as a result of steam cleaning actions after
being in caustic service of equipment manufactured from non-PWHT’d carbon steel.
a. True.
b. False.

35) Nickel base alloys are highly susceptible to the effects of Caustic Embrittlement.
a. True.
b. False.

36) There is no difference between Caustic Embrittlement and Caustic Stress Corrosion
Cracking.
a. True.
b. False.

37) Which of the following materials are considered susceptible to the effects of Sulfide
Stress Cracking?
a. Nickel based alloys.
b. Low alloy steels.
c. 300 Series SS.
d. All of the above.

38) Blistering caused wet H2S environment results from hydrogen generated by corrosion,
not hydrogen gas from the process stream.
a. True.
b. False.

39) Write out the following acronym in full: HIC

40) Write out the following acronym in full: SOHIC

41) High temperature hydrogen attack results from exposure to hydrogen at elevated
temperatures and low pressures.
a. True.
b. False.

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42) Select in order of increasing resistance to High temperature hydrogen attack:

a. 3Cr-1Mo, 2.25Cr-1Mo-V, 1Cr-0.5Mo, Carbon steel.
b. Carbon steel, 1Cr-0.5Mo, 2.25Cr-1Mo-V, 3Cr-1Mo.
c. Carbon steel, 2.25Cr-1Mo-V, 1Cr-0.5Mo, 3Cr-1Mo.
d. 2.25Cr-1Mo-V, Carbon steel, 3Cr-1Mo, 1Cr-0.5Mo.

43) Consider the following statement and select the appropriate option as a response. 300
Series SS is considered to be immune to all forms of CUI.
a. True, because SS does not react with water.
b. True, because CUI is only affect CS and low alloy steels.
c. False, CUI can be found in the form of Cl-SCC.
d. False, CUI can be found in the form of SCC if anhydrous ammonia is present.

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