API 570 EXAM ... 19 DMs from API 571 ‘ome _[ Damage Mechanism ‘om | Damage Mechaniem + | suiaation 34 _| Softening (Spneroidization) 2 | Gohstenngiite/SOHIcSSC) eal eeeeenmeeenmennem: J 4 —[ High tomp Has Corrosion 37 —[Hydrofiuerie Acid Corrosion 3 [ Povthionte Acid Crackina 30 | Fiue Ges Dew Point Corasion 3 | Ammonium Chionde Corrosion 21 | Deatioving (Dezinetieation’ Denickeificaton) 10 | Hoh Temperature Hydrooen Attack 43_| Corrosion Fatigue: 14 | Retractory Degraaavon 47_[ Atmospnene Corrosion: 15 _[Graphitzaton a0, 20 = 24__| Corourzation. i 37 | Taniam Hydnging to 25 | Hydrogen Embaitoment sa | Soa 26 | Steam Blanksting ‘59 | Metal busting 37__| Thermal Shack 60 | Stron Aone = ‘Congaign (ees Dealoyina) GO| Phosphoric Acid Corrasion — a 30 | Shor term Overheating = Stres= Rupture 63_| Phenol (earbaiie neid) Corrosion 32 _| Sioma Phase’ Chi Embrtamant 165 _| Oxyger-Enhanced ignition and Combustion 23 _| e8st «475°C) Embnitiement ee Sy, ‘API Recommended Practice 871, Damage Mechanisms Affecting Fixed Equipment in the Refining Industry, SECOND EDITION, April 2011 ATTENTION: Only the followisig mechanisms listed in RP 571 are included on the exam: Section 3, Definitions Par. 4.2.7 - Brittle Fracture 429 - Thermal Fatigue 42.14 — Erosion Erosion Corrosion 4.2.16 —_Mechanical Fatigue 4.2.17 — Vibration-Induced Fatigue 43.1 — Galvamie Comrosion 43.2-~Atmosphenie Corrosion 433 ~ Contosion under Insulation (CUD 43.5 Boiler Water Condensate Corrosion 43,8 — Microbiologically Induced Corrosion (MIC) 43.9 Soil Corrosion 43.10 ~ Caustic corrosion (aew!) 4.42=Sulfidation 4.5.1 ~ Chloride Stress Corrosion Cracking (CSCC) 453 ~ Caustic Stress corrosion Cracking (Caustic Embrittlement) S.1.1.4— Hydrochloric Acid (HCL) Corrosion (new!) 5.1.1.10 ~ Sour Water Corrosion (Acidic) (new!) 5.1.2.2 Amine Stress Corrosion Cracking (new!) 5.13.1 —High Temperature Hydrogen Attack (HTTA)WHERE DO THESE API 570 EXAM QUESTIONS ON DAMAGE MECHANISMS/DETERIORATION COME FROM? The answer is easy > If you look carefully in AP! 570! ‘API 570, Paragraphs 5.4.1.3 & 5.4.2 (Damage Mechanisms) 5.4.1.3 Detailed information concerning common damage mechanisms (critical factors, appearance, and typical inspection and monitoring techniques) is found in APLS74 [5] and other sources of information on damage mechanisms included in the bibliography. Additional recommended inspection practices for specific types of damage mechanisms are described in API574 (7]. Expect about 15 questions or more from these sections on 570 exams! CRITICAL STUDY TIPS YOU MUST UNDERSTAND Tip # 1> Study API 574, Section 7.4 in entirety ... There are 10 subsections > Review! Tip # 2 > Study API 571 (for 19 DMs) focusing on Critical Factors, Appearance & Inspection & Monitoring Techniques > Also study Description of Damage Par. 3 Definitions (Reference only), 4.2.7 — Brittle Fracture, 4.2.9 - Thermal Fatigue, 4.2.14 — Erosion/Erosion Corr, 4.2.16 - Mech Fatigue, 4.2.17 — Vibration Induced Fatigue, 4.3.1 - Galvanic Corr, 4.3.2 ~ Atmospheric Cort, 4.3.3 - Corrosion under insulation (CUI), 4.3.5 — Boiler Water Condensate Corrosion, 4.3.7 ~ Flue Gas Dew Point Corrosion, 4.3.8 — Microbiological Induced Corrosion {MIC} , 4.3.9 Soil Corr, 4.3.10 — Caustic Corr, 4.4.2 Suifidation, 4.5.1 ~ Chloride SCC, 4.5.3 — Caustic SCC (Caustic Embrittlement) 5.1.1.4 — Hydrochloric Acid (HCL) Corr, 5.1.1.10 - Sour Water (Acidic) Corrosion 5.1.2.2 -Amine SCC, & 5.1.3.1 — High Temp Hydrogen Attack (HTTA) Tip #3 > Items repeated again and again i 574 & 571 sections are likely exam questions Tip #4 > Items having figures or illustrations of the damage (unusual descriptions like spider- web cracking) are very likely exam questions 7.4 Inspection for Specific Damage Mechanisms (API 574) Oil refinery and chemical plant piping can be subject to internal and external damage mechanisms. This piping carries a range of fluids that can be highly corrosive, erosive, and prone to SCC or subject to material degradation in service. In addition, both aboveground and buried piping is subject to extemal corrosion. The inspector should be familiar with the potential damage mechanisms for each piping system. API 571 has been developed to give the inspector added insights on various causes of damage. Figure 18, Figure 19, Figure 20, and Figure 21 illustrate several examples of corrosion and erosion of piping. IF an inspection of an area of piping indicates damage is occurring, the piping upstream and downstream of this area, along with associated equipment, should also be inspected. Additionally, if deterioration is detected in pressure equipment, associated piping should also be inspected.7.4 Inspection for Specific Damage Mechanisms (API 574) Each owner/user should provide specific attention to the needs for inspection of piping systems that are susceptible to the following specific types and areas of deterioration: a) Injection points > Study Section 7.4.1 > API570, Section 5.9 & Figure 1 b)} Process mix points > Study Sect 7.4.2 > API570 Table 3, Note A, for Injection/Mix points c) Dead-legs > Study Section 7.4.3 & also API S70, Section 5.5.9 d) CUI > Study Section 7.4.4 > API 570, Sect 5.5.6 incl. Table 3 (susceptible API 574 temps) Action: Transfer susceptible temperature ranges from API 574 into API 570 Table 3 (Margins ©) S/A interfaces > Study Section 7.4.5 > API 570, Section 9 for buried piping in entirety f Service specific and localized corrosion > Study Section 7.4.6 found throughout API 570 8) Erosion and erosion-corrosion > Study Section 7.4.7 & h) Environmental cracking > Study Section 7.4.8 i) Corrosion beneath linings and deposits > Study Section 7.4.9 j) Fatigue cracking > Study Section 7.4.10 k) Creep cracking > Study Section 7.4.11 I) Brittle fracture > Study Section 7.4.12 m) Freeze damage > Study Section 7.4.13 1} Contact point corrosion > Study Section 7.4.14 ©} Dew-point corrosion “> Dew point corrosion does NOT have its own section ... See API 571 Critical API 570 Corrosion Related Definitions 3.1.33 injection point: Injection points are locations where chemicals or process additives are introduced into a process stream. Corrosion inhibitors, neutrelizers, process anti-foulants, Desalter demulsifiers, oxygen scavengers, caustic, and water washes are most often recognized as requiring special attention in designing the point of injection. Process additives, chemicals and water are injected into process streams in order to achieve specific process objectives. NOTE Injection pi 3.1.52 mix points: Process mix points are points of joining of process streams of differing composition and/or temperature where additional design attention, operating limits, and/or process monitoring are utilized to avoid corrosion problems, Not all process mix points are problematic, but they need to be identified/evaluated for possible degradation mechanisms. its do not include locations where two process streams join (mix points). 3.1.16 deadlegs: Components of a piping system that normally have no significant flow. Some examples include blanked branches, lines with normally closed block valves, lines with one end blanked, pressurized dummy support legs, stagnant control valve bypass piping, spare pump piping, level bridles, relief valve inlet and outlet header piping, pump trim bypass lines, high- point vents, sample points, drains, bleeders, and instrument connections.Critical API 570 Corrosion Related Definitions 3.1.87 soil-to-air interface (S/A): An area in which external corrosion may occur on partially buried pipe. NOTE: The zone of the corrosion will vary depending on factors such as moisture, oxygen content of the soil, and operating temperature. The zone generally is considered to be from 12 in. (305 mm) below to 6 in, (150 mm) above the soil surface. Pipe running parallel with the soil surface that contacts the soil is included. 3.1.28 general corrosion: Corrosion that is distributed more or less uniformly over the surface of the piping, as opposed to being localized in Nature 3.1.44 localized corrosi ited area of the metal surface. \eterioration, e.g. corrosion that is confined to a MUST KNOW (MEMORIZE) ... INJECTION POINTS When designating an injection point circuit for the purposes of inspection, the recommended upstream limit of the injection point circuit is a minimum of 12 in. (300 mm) or three pipe diameters upstream of the injection point, whichever is greater. The recommended downstream limit of the injection point circuit is the second change in flow- direction past the injection point, or 25 ft (7.6 m) beyond the first change in flow direction, whichever is less. In some cases, it may be more appropriate to extend this circuit to the next piece of pressure equipment, as shown in Figure 22. During periodic scheduled inspections, more extensive inspection should be applied to the injection point circuit in an area beginning 12 in. (300 mm) upstream of the injection nozzle and continuing for at least 10 pipe diameters downstream of the injection point. CONDITION MONITORING LOCATIONS = CMs The placement of CMs within injection point circuits subject to localized corrosion should be in accordance with the following guidelines: a) Establish CMLs on appropriate fittings within the injection point circuit, b) Establish CMLs on the pipe wall at the location of expected impingement by the injected fiuid, c) CMLs at intermediate locations along the longer straight piping within the injection, point circuit may be required, d) Establish CMLs at both the upstream and downstream limits of the injection point circuit. The preferred methods of inspecting injection points are radiography and/or ultrasonic, as appropriate to establish the minimum thickness at each CML. STUDY THE HIGHLIGHTED API 570 SECTIONS Now Review Questions ... Cover answers ... Don’t peek!: Study 5 ver answ DM# 1 of 66... SULFIDATION > 11 questions ition damage is accelerated by the presence of: la. Si A) Hydrogen B) Sulfur ©) Salts D) Corrosive Water Ib. Which mater highly resistant to 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. & 4.4.2.3.d ... Affected Materials & Critical Factors Je, Sulfidation of iron-based alloys usually begins at metal temperatures above: A)500°F (260°C) B) 700°F (370°C) ©) 900°F (482°C) —_D) 1000°F (538°C) 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% ©)7-9% D) 12% Je. Which Curves are utilized to determine Sulfidation corrasion rates? ‘A) Couper-Gorman B) MeConomy ©) Nelson, D) None of these 1f, Sulfidation oceurs at high temps and is primarily caused hy: A) Sulfates & other reactions from decomposition of sulfur compounds at high temps B) SO? & other reactions from decomposition of sulfur compounds at high temps ©) SO’ & other reactions from decomposition of sulfur compounds at high temps D) H’S & other reactions from decomposition of sulfur compounds at high tempsDM#1 1g. When Sulfidation damage is found, it most often (usually) appears as: A) Localized corrosion B) High velocity erosion-cortosion C) Uniform thinning D) Under-deposit (scale) corrosion Ih. Services susceptible to sulfidation ¥ 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 Ji, 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 ... Sec Paragraph 4.4.2.6 below (Prevention) 1j. What will be the approximate corrosion rate for a new yessel constructed of 5% Chrome at a design temp of 700°F (370°C) operating in a 1% Sulfur Process stream | A) 10.5 MPY B) 15 MPY ©) 18 MPY D) None of these 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 APL578 ©) Proactive PMI programs for alloy verification per API 578 D) Alloy verification checks (chemical analysis) per API 578 End of DM # 1 > How did you do on 11 questions? Did you peak at the answers? Score yourself honestly! 6DM#5 ... PASCC (Polythion id SCC) > 2 Q&A 5a. A form of SCC normally occurring during shutdowns, startups or during operation when crackin; acids forming from sulfide scale, air and moisture acting on sensitized st A) Caustic B) Chloride SCC ©) Polythior 1D) Flue Gas Dew Point Corrosion Sb. In order for PASCC to occur the material must be: A) PWHT'd B)Non-PWHT'd —C) Sensitized D) Austenitic SS NOTE PASCC IS INCLUDED AS IT IS COVERED IN BOTH CODE & API 574 570... Para 5.8.1 | 574 Para 7.4.8DM# HCL Corrosion > 10 Q&A 9a. Hydrochloric acid (aqueous HCI) 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 ©) 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 Ans -1.1.4.1.a ... HCL Corrosion >Description of Damage 9b. Which of these is FALSE regarding Hydrochloric acid Corrosion damage in refineries? B) — in refineries is most often associated with condensed salt i corrosion Answer: B ... Ref: $.1.1.4.1-b ... HCL Corr >Deseription of Damage > Dew Point Corr exists in vapor condensing conditions and co: water droplets become highly acidic 9c. Regarding Hydrochloric acid Corrosion, which of these are critical factors? A) HCI acid concentration, temperature and alloy composition B) HCI acid and water concentrations, temperature and alloy composition ©) HCI acid and water and salt concentrations, pH, temperature and alloy composition ‘D) None of these are correct Answer: A... Ref: 5.1 -1.4.3.a ... HCL Corr > Critical Factors. 94. The severity of Hydrochloric acid (HCI Corrosion will: A) Decreases with increasing HCI concentrations and deereasing temperatures B) Decteases with inereasing HCI concentrations and inereasing temperatures ©) Inereases with inereasing HCl concentrations and decreasing temperatures D) Increases with increasing HCI concentration and increasing temperatures 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)25 B45 O55 D)7.0DM #9... HCL Corrosion > 10 Q& 9£, Which materials have the best resistance against Hydrochloric Acid (HCD) Corrosion? A) Carbon steel and Low alloy Steels B) 300 series SS & 400 series SS C) Nickel-based alloys D) Copper Alloys Answer = € ... 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 HCI at any concentration or temp 9g. Refinery Units where HCl acid corrosion is found include which of these? A) Hydroprocessing units, catalytie reformer units, alkylation units & emude units B) Hydroprocessing units, catalytic reformer units, amine units & vacuum units C) Hydroprocessing units, catalytic reformer units, vacuum units & crude units D) Hydroprocessing units, catalytie reformer units, amine units & erude units Answer: C ... Refi 1.1.4.4 in 1* Para. & 5.11.46 ... HCL Corr Affected Units or Equip 9h. HCl acid corrosion damage can appear as any of the following types 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 1D) 300 Series S$ and 400 Series SS will often suffer pitting attack ane Answer Ref: 5.1.1.4.5.ab ... HCL Corrosion > Affected Units or Equipment 91. rrosion damage in locally thinned areas can be best detected by: A) Profile radiography B) VI where possible and UT thickness readings C) Automatic ultrasonic scanning methods or profile radiography D} Strategically placed cortosion probes & UT thickness readings 9). Which of these are important aspects of a wé effects of HCl corrosion? leveloped program to minimize the A) Establishing IOWs B) Process and Corrosion monitoring C) Strategically placed corrosion probes/eoupons D) None of these are correct Anower: B.. Ref: 5.1.14,7.ale ... HCL Corrosion > Inspection & Monitoring End of DM # 9 > How did you do on 10 question:DM # 10 —- HTHA (Hi-temp hydrogen attack) > 7Q&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) HRS. B) NHsHS. c) CHs D) None of these 10b. Regarding HTHA, hydrogen at elevated temps/pressures reacts with elements to form this gas that cannot diffuse through steel, causing an overall loss in strength? A) Hydrogen reacts with the hydrogen dioxide in steel to create oxidation and damage B) Hydrogen reacts with the hydrogen dioxide in steel to ereate HS and damage ) Hydrogen reacts with carbides in steel to form methane (CH) and damage D) Hydrogen reacts with the carbides in steel to create oxidation and damage Answer Ref: 5.1.3.1.1.2 > Methan 10¢. Regarding HTHA, which of these are critical factors for a specific materi: tion of Damage A) Temperature, H2S concentrations, pressure, time and stress. B) Temperature, hydrogen partial pressure, time and stress C) Temperature, H2S concentrations, time and sttess D) None of these are correct Ref: 5.1.3.1.3.a ... HCL 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 4 % Moly, B) At least 2.25% Cr and 1% Moly ©) At least 5% Cr and 1% Moly 1D) At least 7% Cr and 1% Moly are not susceptible We. Due to HTHA considerations, what steel alloy is no longer recommended for new construction in hot hydrogen services? A) Mn Mo B)C-0.5 Mo ©) 1Cr4 Mo D) 1% Crs Mo Answer =B .., See Paragraph 5.1.3.1.6.c&d below > HTHA > Prevention/Mitigation 10f. Which Curves are utilized to determine safe operation regarding HTHA? A) Couper-Gorman _B) MeConomy. ©) Nelson D) None of these 10g. HTHA damage is usually detected (determined) by which of the following methods? A) UT velocity ratio & backseatter B) MT or PT ©) WEMT D)RT 10M # 12... THERMAL FATIGUE > 10 Q&. 12a. Which Mechanism is the result of cyclic stress caused by temperature variations? A) Creep B) Thermal Fatigue C) Cyelie Cracking psc 12b. Key factors affecting Thermal Fatigue are: A) The magnitude of the temperature swing and frequeney (number of eyeles) B) The magnitude of the temperature swing and the time in service C) Temperature, time in service and material D) None of these are correct 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 ©) No set limits or temperature rules apply to Thermal Fatigue D) When temperature swings (cycles) exceed 200°F (93°C) 12d. Which damage mechanism has been @ major problem on coke drum shells, and particularly in the area of the supporting skirt near the shell? A) Thermal fatigue B) Erosion/Corrosion ©) 85°F Embrittlement D) Temper embrittlement Answer Ref: Par, 412.0.4.b & Figs. 4-12/4-13 ... Affected Units or Equipment ‘Thermal Fatigue (coke drums) has 2 figures & is also found in the PEDs 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) CO* Corrosion B) Erosion/Corrosion C) Condensate Corrosion D) Thermal Fatigue Answer =D... See Para. 4.2.9.4. > Thermal Fatigue > Affected Units or Equipment uwM #12... THERMAL FATIGUE > 10 Q&. 121. WI +h 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 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 ©) Cracks are usually transgranular with a spider web appearance D) Cracks usually initiate on the surface of the component Ans Ref: 4.2. aalb > 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 D) None of these are correct 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, ) Monitor thermal expansion D) None of these are correct Answer =B ... See Paragraph 4.2.9.6.a.ii > Prevention > Thermal Fatigue 1j. 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 ©) Monitor thermal expansion and eyeling D) Nong of these are correct Answer = A... See Paragraph 4.2.9.7. > Insp & Monitoring > Thermal Fatigue End of DM # 12 > How did you do on the 10 Q: 12DM # 13 UR WATER (ACIDIC) CORR SQ&A 13a. Corresion of steel due to Acidic Sour Water containing H’S tends to occur at: A)pH>7 B) pH>2 C)pH>3 D) pH> 4.5 13b. Which of these choices include all critical factors for Sour Water (acidic) corrosion, ‘A) HS content, pH, temperature, velocity and oxygen concentration B) HDS content, pH, temperature and oxygen concentration C) HRS content, pH, temperature D) None of these 13c. Regarding acidic corrosion, at a given pressure, E?S concentration in sour water ‘A) Increases as the temperature increases B) Increases as the temperature decreases C) Decreases as the temperature increases D) Decreases as the temperature decreases 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 oceur, especially if CO2 is present ©) Corrosion in CO2 containing environments may also be accompanied by Carbonate SCC D) 300 Series SS is susceptible to pitting & may experience erevice corrosion & Chloride SCC 13d. 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 13DM #18 ... CAUSTIC (SCC) CRACKING > 7Q&A 18a. Another name for Caustic Stress Corrosion Cracking (SCC) A) Alkaline SCC B) Caustic Gouging C) Ductile gouging D) None of these 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 1D) Mostly adjacent to zones of high stress 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) 02 content, caustic strength & stress levels. __D) None of these 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 ©) Increasing concentrations & decreasing temps increases likelihood/severity of cracks D) Increasing concentrations & increasing temps increases likeliliood/severity of cracks 18e. Caustic concentrations at what minimum ppm values can cause Caustic SCC? A)50-100PPM —-B) 100-150 PPM =—C) 150-200 PPM ~—_—D) 200-250 PPM Answer =A ... Ref: 4.5.3.3.¢ > PWHT prevents Caustic SCC ... Critical Factors 18g. How can Causti A) Upgrade to 300 Series SS B) Upgrade to the nickel alloy C) Avoid steamout cleaning D) None of these 19f. Which of these actions are required for a piping system with a 30% Caustic Solution operating at 140°F (OPEN BOOK QUESTION REPORTED)? A) Use Nickel alloys B) Use CS and PWHT is necessary C) Use CS and PWHT is not necessary ‘D) None of these are correct ress Corrosion Cracking he prevented on Non-PWIHT'd CS lines? 14DM #19 ... CAUSTIC CORROSIOND TQ&A 19a. Localized corrosion due to the concentration of caustic or alkal occurs under evaporative or high heat transfer conditions is called: A) Alkaline Sour Water Corrosion B) Caustic Corrosion ©) HCL Corrosion 1D) None of these 19b. Which statement is FALSE regarding Sources of Caustic Corrosion? A) A concenirating 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 oF process equipment C) Process units use caustic solutions for neutralization & sulfur or chlorine compound removal 19c. Caustic may become concentrated (causes corrosion) by any of these means EXCEPT: A) DNB B) Evaporation C) Deposition D) Precipitation 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 19¢, Caustic Corrosion may appear as any of these EXCEPT: A) General metal loss (In boiler tubes) B) Grooving at top of tube (Ia horizontal tubes) ©) Localized metal loss (locally thinned under deposits) D) Localized gouging along a waterline (circumferential grooves in vertical boiler tubes) 19f. Improved caustic corrosion resistance above 150°F can be achieved by selecting: A)LA Steel B) Alloy 400 €) 300 Series SS D) Cast stainless Answer = B ... See Para. 4.3.10.6.c ... Caustic Corr ... Prevention/Mitigation) 19g. Which materials given below are the least susceptible to caustic corrosion? A) Carbon Steel B) LA steel C) 300 Series D) Nickel-based alloy Answer =D ... Refi 4.3.10.2 & 4.3.10.6.¢ ... «.. Caustic Corr ... Affected Materials & P/M 15DM #20 ... EROSION/EROSIO 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 20b. Metal loss that is the result of impact or abrasion with contributing corrosion is called: A) Pitting B) Erosion © Corrosion D) Erosion/Corrosion 20¢. Pure erosion is very rare and is sometimes referred to as: A) Abrasive wear B)Undercutting _—_C) Tigerstriping DD) None of these 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) Frosion-corrosion ©) Erosion and erosion-corrosion D) NAC and erosion and erosion-cortosion Ans: B ... API 571, Para. 4.2.144.d > Erosion/Erosion-Corrosion ... Affected equipment 42.145 Appearance or Morphology of Damage MUST KNOW THE ABOVE APPEARANCE ... Question 20g to be developed 20f. 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 ©) 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 20g. Heat exchangers u re which of these components to minimize erosion problems? A) Impingeinent plates, tube ferrules, horizontal baffles and pass partition plates B) Impingement plates, tube fervules, and horizontal baffles only C) Impingement plates and tube ferrules only D) Impingement plates only Answer: C ... API S71, Par. 4.2.14.6.d — Erosion/Erosio: .. Affected equipment 16M # 22... AMINE CRACKING > 6 Q&A 22a. In aqueous alkanolamine systems used to remove/absorb E’S and/or CO? 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 ) Temperature and corrosion D) Tensile stress and corrosion 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 22¢. 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 224. 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 eracks B) Decreasing temperatures & stress levels increases the likelihood & severity of eracks C) Increasing temperatures & stress levels decreases the likelihood & severity of cracks D) Increasing temperatures & stress levels increases the likelihood & severity of cracks 2c. 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)IPS B) Wet IPS ©) Stress D) Temperature 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 HS environment or CO2 carryover ©) Exposed to steamout or organic acid carryover ‘D) None of these are correct 7DM #23 ... CHLORIDE SCC 5Q&A 23a. Which of the following materials is susceptible to Chloride SCC? A) Carbon steel B) 300 Series SS ©) Low alloy steel D) 400 Series SS 23b. Critical factors for Chloride SCC include all of the following EXCEPT: ‘A) Chloride content B) pH & temperature ©) Alloy composition D) Stress & presence of CO* Answer =D ... Para. 4.5.3.2 ... Chloride SCC > Critical Factors > stress, 02 presence 23e. Regarding Chloride SCC, which of the statements below is TRUE? A) Increasing temperatures & chloride levels increase susceptibility for eracking B) Decreasing temperatures all but eliminates the susceptibility for cracking C) Decreasing temperatures increases the susceptibility for cracking D) None of these are correct Answer: A... Reference: 4.5.1,3.b/e.., Chloride SCC > Critieal Factors > APT siyle 0 23d. Chloride SCC usually oceurs above what metal temperature and pH value? A) Above 125° F (52°C) and pH 3.0 B) Above 140° F (60°C) and pH 2.0 C) Above 175° F (79°C) and pH 2.5 D) Above 200° F (93°C) and pH 3.0 23e. Regarding Chloride SCC, which statements regarding nickel content are true? A) Greatest susceptibility (©3%), highly resistant (2 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 (© 459%), no % immune from SCC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 © Brittle fracture D) Temper Embrittlement 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 3ic. 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 fo crack like flaws) as measured in Charpy impact test B) Material tensile strength (resistance to crack like flaws) as measured in a tensile test ©) Size, shape and stress concentration effect of a flaw 1D) Amount of residual and applied stresses on the flaw: 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 oc C) Temperatures below ambient and only in thick sections D) Temperatures below Charpy Impact transition temperatures 19DM #31... BRITTLE FRACT 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 ©) Spheroidization D) Brittle fracture 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 3g. Regarding evidence of: le fractuy failures, cracking found by the Inspector will typically show ‘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 eracks with evidence of a shear lip or localized necking at cracks 1D) None of these are correct 31h. Some reduction in the likelihood of a Brittle Fracture may be accomplished by performing all of the following except: A) Performing PWHT on @ weld repaited/modified vessel in service when PWHT was not done B) Performing PWHT on a vessol 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. > Prevention/Mitigation 20DM #46 ... CORR UNDER INSL (CUT) 5SQ&A 46a. 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 (SO, ete) 46b. CUI becomes more severe at this metal temperature range (where water is less likely to vaporize and insulation stays wet longer) between (Note: Give the 2003 Edition value): A) 212°F (100°C) to 250°F (121°C) B) Ambient to 212°F (100°C) ©) 212°F (100°C) to above (unlimited) DD) 212°F (100°C) to 350°F (177°C) 46c. Regarding CUL, corrosion rates will: A) Decrease with inereasing metal temps up to the point where water evaporates quickly B) Increase with increasing metal temps up to the point where water evaporates quickly ©) Stay the same regardless of the temperature where water evaporates quickly D) None of these are correct (6d. Location of equipment is a concern for CUI and 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 ©) Areas where acid vapors are present D) All of the above are correct 46e. Prevention of CUI is best achieved by: A) Carefully planned periodic inspections B) Careful visual exam of insulation covers C) Employment of quality coatings DyNone of these are correct 21IM # PHERIC CORROSIO. A 47a. Which statement is FALSE regarding atmospheric corrosion? A) Marine environments are the most severe B) Dry rural environments cause very little corrosion. C) I'S a form of corrosion that occurs from moisture associated with CUL D) Moist polluted industrial environments with airbome contaminants aré also the most severe 47b. 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) Usually too dry for corrosion to oceur B) Susceptible to conditions that cause inereased corrosion rates €) Susceptible to conditions that cause decreased conosion rates D) Usually too dry for corrosion to occur, except under insulation (that ean remain wetted) 22DM #50 ... BOILER WATER CO! CORR. 50a. The commen method of insp and monitoring for boiler water condensate corrosion is: A) Analysis of water B) Analysis of treatment chemicals C) Analysis of operating temperature D) Analysis of pH 43.5.5 Appearance or Morphology of Damage a) Corrosion from oxygen tends to be a pitting type damage and can show up anywhere in the system evenif only very small quantities the Scavenging treatment. Oxygen is particularly aggressive in equipment such a5 closed h oe swhere there is axapid water temperature rise, b) Corrosion in the condensate to be due to carbon dioxide although some oxygen pitting problems can oceur ifthe ;venging treatment is not working correctly. Carbon dioxide corrosion tends to be a smooth ‘of the pipe w: Parameters which can be monitored for signs of upset include the pH, conductivity, chlorine or residual biocide, and total dissolved solids to check for leaks in the form of organic compounds. b) There are no proaetive inspection methods other than developing an appropriate program when problems such as a ruptured boiler tube or condensate leaks are recognized in the various parts of complex boiler water and condensate systems. ©) Deaerator éracking problems can be evaluated off ine at shutdowns (usé proper WEMPT methods} 23M # 51... MICROBIOLOGICALLY I. 51a... 4.3.8.1 Description of Damage b. 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 1D) None of these are correct Sic. This DM is usually found in aqueous environments or services where water is sometimes or always present, especially where stagnant or low-flow conditions allow the growth of microorganisms: A) Microbiologieally Induced Corrosion B) Boiler water condensate corrosion ©) Sour water corrosion 1D) Cooling water corrosion 51d. Regarding MIG, different organisms thrive on different nutrients incl. inorganic substances (Sulfur, HPS), 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 24DM #51... MICROBIOLOGICALLY INDUCED CORR Sle ...43.8.5 Appearance or Morphology of Damage a) MIC corrosion is usually observed as localized pitting under deposits or tubercles that shield the organisms. SIf ...4.3.8.5 Appearance or Morphology of Damage Sig. Regarding prevention of MIC, Microbes require water to thrive. Systems that contain water (cooling water, storage tanks, etc.) should be treated with any of these items except: A) Reverse Osmosis B) Proprietary compounds ©) Ozone and ultraviolet light D) Biocides (such as chlorine, bromine) Answer: A ... API S71, Para. 4.3.8.6. > MIC .., Prevention/Mitigation Sih. Inspection and Monitoring for MIC is done by any of the following measures in Cooling Water (CW) systems except: A) In CW systems, treatment effectiveness is monitored (measure microbe counts) B) In CW systems, treatment effectiveness is monitored (measure biocide residuals) C) In CW systems, treatment effectiveness is monitored (visual appearance is checked) D) In CW systems, treatment effectiveness is monitored (special probes monitor fouling) Answer: D ... API S71, Para. 4.3.8.7.a/b > MIC ... Inspection & Monitoring 25,DM #53... GALVANIC CORROSION Galvanic Series Table below (See page 4-103) 8Q & A 26Corroded End Anodic—More Active Magnesium Magnesium alloys Zine Aluminum Aluminum alloys Steel Cast iron Type 410 SS (active state) Ni-Resist ‘Type 304 SS (active state) Type 316SS, (active state) Lead Tin. Nickel Brass. Copper Bronze Copper-Nickel Monel Nickel (passive state) Platinum: Protected End—Cathode - More Noble DM #53 ... GALVANIC CORROSION 7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-Niekel to Bronze connection _B) Steel to Aluminum connection C) Steel to Titanium connection 1D) Brass to Bronze connection Itis 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! > 2m rule for 30% extra coating applies to all thin filmed coatings (= 500 microns or 20 mils) where anodes attach EXERCISE 53 ... G. ANIC CORROSION (8 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 ©) Dissimilar alloys (anode and cathode) in contact with one another D) Dissimilar alloys (anode and cathode) in contact with an electrolyte 2. Corrosion rates of anodes will be less (less affected) if there is a: A) Small anode to cathode ratio B) Large anode to cathode ratio ©) Sinall cathode to anode ratio D) Large cathode to anode ratio 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, ©) Soil Corrosion D) None of these Answer! D... Reference: 4.3.1.1 > Galvanic Corrosion is correct (Description of Damage) EXERCISE 53... G. 284. For galvanie corrosion to occur, which of the following items is NOT REQUIRED? A) Presence of an electrolyte of 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 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, ete), 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 6. Which of the following statements is NOT TRUE regar morphology of damage for galvanic corrosion? 1g the appearance or 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 7. Galvanic corrosion is the principle used in galvanized steel, where the Zine (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 jonship reverses at water temperatures over A) 150°F (66°C) B) 200°F (93°C) ©) 210°F (99°C) D) None of these temperatures as it never reverses Answer: A ... Reference: 4.3.1.6.c > (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) Visual inspection, RT and UT thickness 29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 S4b. 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 erack 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 D) None of these are correct 54c. Most important factor in determining component’s resistance to Mech Fatigue is: A) Material B) Design ) Operation D) Time 3056a. Cause for cracking on %4” NPS CS high point vent on steam relief line is likely due to: ‘A) Mechanical Fatigue B) Vibration-induced fatigue ©) Stress Corrosion Cracking D) Original fabrication weld defect S6b. 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 6c. 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 call A) Corrosion fatigue B) Frosion-corrosion fatigue ©) Vibration-induced fatigue D) None of these are correct (6d. 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 components natural frequeney B) Cracking problems from vibration-induced fatigue usually initiate at stress raisers or notches C) The amplitude and frequeney 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.ale ... allows vibration and possible ... (Critical Factors) 56e. Regarding vibration-induced fatigue, affected Units or Equip include all these exeept: 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 ©) Branch connections with valves, drop control valves, and steam reducing stations D) Heat exehanger tubes susceptible to vortex shedding Answer = C ... See VIF, P: ‘or Equipment) > Typo Ok 4.2.17.4.alble/dle (Affected U1 31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 ) Definite warning sign of VIF damage is loose refractory visible at low points D) Definite warning sign of VIF damage is anchoring system exposure 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 ) Insialll gussets/stiffeners on small bore connections D) Eliminate unnecessary small bore connections Answer = B ... See VIF, Para. 4.2.17.6.a/b/e/d ... €an 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) Cheek for audible sounds of vibration from piping components (control valves & fittings) ©) 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.alb/e/d ... may indicate excessive (Insp & Monitoring) 56i. Inspection & Monitoring strategies for Vibration-Induced Fatigue should include all of the following measures except: A) Cheek for visible signs and evidence of vibration, pipe movement or water hammer B) Cheek for insulation jacket damage (which is a definite indicator of excessive vibration) ) Cheek 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, ete.) for intermittent vibrating conditions 32DM #58 ... SOIL CORROSION > 10 Q&A he deteri 1n of metals exposed to soils is referred to a: 58a, A) MIC B) Soil Corrosion C) Atmospheric Corrosion D) None of these are correct Answer: B... APIS71, 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) None of these are correct Answe .» API S71, Para. 4.3.9.2 > Soil Corrosion ... Affected Materials 58c. Which of these is not a critical factor in soil corrosion? ‘A) Soil temperature, soil texture, and soil moisture B) Cathodie protection and stray current drainage C) Soil resistivity, soil type and homogeneity D) Coating type, age, and condition Ans: A ... Ref: 4.3.9.3.a > Soil Corr (CF = Op temp + Moisture + O? 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 Answer: D ... APLS71, Para. 4.3.9.3.¢ — Soil Corrosion ... Critical Factors 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 Answer: D ... Ref: 4.3.9.3.d > Soil Corro m (Critical Factors) 33,DM #58 IL CORROSION > 10 QO& 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 58g. Soil corrasion rates: A) Decrease with increasing metal temps B) Inerease with decreasing metal temps C)Inerease with increasing metal temps D) Are not affected by the metal temps 58h. Soil corrosion of carbon steel can be minimized through the use A) Corrosion resistant coatings and CP B) Special backfill, coatings and CP C) Effective drainage and CP D) None of the above Answer: B ... Ref: 4.3.9.6 > Soil Corrosion (Prevention/Mitigation) 58i. 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 58). Regarding soil corrosion, CP should be performed and monitored in accordance with: A) NACE RPO169 B) NACE RPO472 C) The owner user's standard D) None of these 34OLD Q&A FOR API 570 EXAM (16 DMS OF API571 & API S74 Points) 1. Cause for cracking on a %” NPS CS high point vent on a steam relief line is likely due to: ‘A) Mechanical Fatigue B) Vibration-induced fatigue ©) Stress Corrosion Cracking 1D) 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 ©) 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 ©) 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 ©) When water temps rise rapidly 1D) When water temps fall below design Answer = C ... See Para, 4.3.5.5. (Appearance or Morphology) 5. Which materials are highly (most) susceptible to Chloride Stress Corrosion Cracking? ‘A) Martensitie SSB) Duplex SS €)300SetiesSS —_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) pET& tempetature C) Alloy composition) Stress & presence of O* Answer =D .., See Para. 4.5.1.3. Critical Factors) ... > stress & presence of oxygen 7. Sulfidation damage is accelerated by the presence of: A) Hydrogen B) Sulfur ©) Salts D) Contosive Water Answer = A’... See Paragraph 4.4.2.1 (Description of Damage) 8. Prevention of CUI is best achieved by: A) Carefilly 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) 35,API570 EXAM (16 DMS OF API 571 & API574 Points) > API 570, PARA. 5.4.1.3 9. Critical Environmental Factors for CUI can include all of the following EXCEPT A) Insulation system design & type B) Humidity & Rainfall ) Chlorides from Marine Environment D) Industrial pollution (S Answer = A ... See Paragraph 4.3.3.3. (Critical Factors) ete) 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. below > Critical Factors 11. Due to HTHA considerations, what steel alloy is no longer recommended for new construction in hot hydrogen services? A) Mn 4 Mo B)14Cr%Mo ©) 1Cr'4 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 ©) Conosion 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 & backseatter_ B)MTorPT C) WFMT D)RT Answer = A ... See Paragraph 5.13.1.7.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 eannot 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) CO? 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)CO* Corrosion B) Erosion/Corrosion C) Condensate Corrosion D) Thermal Fatigue Answer = D ... See Paragraph 4..2.9.4.c > Affected Units or Equipment 36API'570 EXAM (16 DMS OF API 571 & API574 Points) > API 570, PARA. 54.1.3 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 ©) 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) ) Between 212F (100C) & above (unlimited) _D) Between 212F (100€) & 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) BY 500°F (260°C) C) 700°F (370°C)__D) 800 °F (425°C) Answer = B ... See Paragraph 4.4.2.3.c > Critical Pactors 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 plastie deformation? A) 85°F (475°C) Embrittlement B) Temper Embrittlement ©) Brittle Fracture D) Sigina Phase Embrittlement Answer: C ... API571 ... Para. 4.2.7.1 ... Brittle Fracture Question 21. Regarding brittle fracture, when the eritical 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 siress concentration effect of a flaw D) Amount of residual and applied siresses on the flaw Answer: B ... API571 ... Pata, 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 eracks largely without evidence of any associated plastic deformation B) Branching cracks having evidence of a shear lip or localized necking around the eracks C) Both straight & multi-facet cracks with evidence of a shear lip or localized necking at cracks D) None of these are correct Answer: A |.) API571 ... Para. 42.7.5.a ... Brittle Fracture Question 23. The accelerated mechanical removal of surface material as a result of relative movement between, or inpact from solids, liquids, vapor or any combination thereof is known as: A)Etosion _B) Erosion-Corrosion ©) Corrosion D) None of these Answer: A ... API57I, Para. 4.2.14.1.a— Erosion/Frosion-Corrosion Question 37API570 EXAM (16 DMS OF API 571 & API 574 Points) > API 570, PARA. 5.4.1.3 24, Pure erosion is very rare and is sometimes referred to as: A) Abrasive wear B) Undercutting —C) Tiger striping 1D) None of these Answer: A ... API 571, Para, 4.2.14.3 — Erosion/Erosion-Cormosion 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 failuce will typically appear as: A) Single clam shell fingerprint with vertical straight lines directly below the erack initiation site B) Single clam shell fingerprint with rings called beach marks coming from a crack initiation site ©) Concentric lines throughout the entire cross-seetional area D) None of these are correct Answer: B ... API 571, Para. 4.2.16.5.a & Figures 4°30/3 1/32/33 — Mechanical Fatigue Question 27. A mechanical form of degradation in whieh eracks are produced as the result of dynamie loading due to vibration, water hammer, slugging, or unstable fluid flow is known as: A) Vibration-Induced Fatigue B) Thermal Fatigue ©) Mechanical Fatigue D) None of these are correct Answer! A... API 571, Pata/42.17.1 —Vibration-Induced Fatigue Question 28. Inspection & Monitoring strategies for Vibration-Induced Fatigue should include: A) Checks for visible sigas 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. F) Allof the above Answer: B... API571, Para, 4.2.17.7.alb/e/d/e/f/g — Vibration-Induced Fatigue Question Note: No API exam questions will have answers that are “ALL OF THE ABOVE” 38.API570 EXAM (16 DMS OF API 571 & API'574 Points) > API 570, PARA. 5.4.1.3 29. Uni ness Mechanisms include all of these EXCEPT; -m or Localized Loss of ‘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 1D) Caustic Corrosion, Dealloying, Graphitic Corrosion F) 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 (CI-SCC), Ammonia Stress Corrosion Cracking B) Corrosion Fatigue, Caustic Stress Corrosion Cracking (Caustic Embrittlement) ©) 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 airbome contaminants are the most severe, and Dry rural environments cause very little corrosion. This mechanism is: A) Atmospheric Corrosion B) Galyanie Corrosion ©) 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 inereased corrosion rates B) Susceptible to conditions that cause decreased corrosion rates ©) 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. 4.32.3.1- 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 1D) 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) Alllof the above are correct Answer: D ... API 571, Para. 4.3.3.5.a — Corrosion under Insulation Question 39