API 570 EXAM … 19 DMs from API 571

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 WHERE DO THESE API 570 EXAM QUESTIONS ON
DAMAGE MECHANISMS/DETERIORATION COME FROM?
The answer is easy  If you look carefully in API 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 API 571 [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 API 574 [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 Corr, 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 – Sulfidation, 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 in 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 external 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.

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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  API 570, Section 5.9 & Figure 1
b) Process mix points  Study Sect 7.4.2  API 570 Table 3, Note A, for Injection/Mix points
c) Dead-legs  Study Section 7.4.3 & also API 570, 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)
e) 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
g) 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
l) Brittle fracture  Study Section 7.4.12
m) Freeze damage  Study Section 7.4.13
n) Contact point corrosion  Study Section 7.4.14
o) 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, neutralizers, 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 points do not include locations where two process streams join (mix points).
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.
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.

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 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 corrosion: Deterioration, e.g. corrosion that is confined to a limited area of the
metal surface.
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 = CMLs
The placement of CMLs 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
fluid, 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!
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 Instructions: Study Using the Hi-Lite copy of API 571 … Cover answers and test yourself
DM # 1 of 66 … SULFIDATION  11 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 (11 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. What will be the approximate corrosion rate for a new vessel constructed of 5%
Chrome at a design temp of 700°F (370°C) operating in a 1% Sulfur Process stream
(OPEN BOOK EXAM Q)?

A) 10.5 MPY B) 15 MPY C) 18 MPY D) None of these

Answer: C … API 571 Para. 4.4.2.3.c – SULFIDATION  USE BOTH CHARTS … 15 x
1.2 = 18 MPY and using a 9% Chrome would lower the estimated corrosion rate to … 6 x
1.2 = 7.2 or 7 MPY, and you must always use the proper “multiplier” factor = 1.2 in this
case  Use both charts  This question recently appeared on an API 510 exam in 2013!!!

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

End of DM # 1  How did you do on 11 questions?

Did you peak at the answers? Score yourself honestly!
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 DM # 5 … PASCC (Polythionic Acid SCC)  2 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)

NOTE PASCC IS INCLUDED AS IT IS COVERED

IN BOTH CODE & API 574

570 … Para 5.8.1

For sensitized austenitic stainless steel piping subject to polythionic stress corrosion cracking,
consideration should be given to using an alkaline-water solution for pressure testing (see NACE RP
0170).

574 … Para 7.4.8

7.4.8 Environmental Cracking

b) Polythionic acid SCC of sensitized austenitic alloy steels resulting from exposure to sulfide/moisture
condensation/oxygen.

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 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
D) None of these are correct

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

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 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 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
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 Affected Units or Equipment

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

End of DM # 9  How did you do on 10 questions?

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 DM # 10 – HTHA (Hi-temp hydrogen attack)  7 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 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 create H²S and damage
C) Hydrogen reacts with carbides in steel to form methane (CH4) and damage
D) Hydrogen reacts with the 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
D) None of these are correct
Answer: B … 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 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
10e. 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

10f. Which Curves are utilized to determine safe operation regarding HTHA?
A) Couper-Gorman B) McConomy C) Nelson D) None of these

Answer = C … Ref: 4.4.2.3.c & Fig. 4-65 McConomy Curves & 4.4.2.6.a …

10g. 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

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 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
D) None of these are correct

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

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 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
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
C) Monitor thermal expansion
D) None of these are correct

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
D) None of these are correct

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?

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 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 the temperature increases

B) Increases as the temperature decreases
C) Decreases as the temperature increases
D) Decreases as the 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

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

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

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DM # 18 … CAUSTIC (SCC) CRACKING  7 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

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

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

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
Answer = B … 571 Para. 4.5.3.3.b & Fig 4-146  Caustic Embrittlement = Open Book

14
 DM # 19 … CAUSTIC CORROSION 7 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) Alkaline Sour Water Corrosion B) Caustic Corrosion
C) HCL Corrosion D) None of these

Answer = B … 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
C) 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. Caustic may become concentrated (causes corrosion) by any of these means EXCEPT:

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

19f. Improved caustic corrosion resistance above 150°F can be achieved by selecting:
A) LA Steel B) Alloy 400 C) 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 SS D) Nickel-based alloy

Answer = D … Ref: 4.3.10.2 & 4.3.10.6.c … … Caustic Corr … Affected Materials & P/M

15
 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 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

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

4.2.14.5 Appearance or Morphology of Damage

a) Erosion & 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.

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
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
20g. 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
16
 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
D) None of these are correct

Answer: A … Reference: 5.1.2.2.3.f … Critical Factors

17
 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
D) None of these are correct

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

c) Characteristic stress corrosion cracks have many branches and may be visually detectable by a
CRAZE CRACKED APPEARANCE of the surface (Fig 4-78, Fig 4-79 and Fig 4-80).
MUST KNOW FOR EXAM

18
 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

31c. 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

19
 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
D) None of these are correct
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
Add on  2-1/4 Cr that have been Temper Embrittled are highly susceptible to BF on
hydrotest See API 574 Para 7.4.12 & API 570 Section 5.8.3

20
 DM # 46 … CORR UNDER INSL (CUI)
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 (SO², etc)

Answer = A … See Paragraph 4.3.3.3.a (Critical Factors)

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)

C) 212°F (100°C) to above (unlimited) D) 212°F (100°C) to 350°F (177°C)

Answer = D … See Par. 4.3.3.3.d … Will change in 2011 2nd Edition = 350F (175C)  CF

46c. 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 temperature where water evaporates quickly
D) None of these are correct

Answer: B … Ref: 4.3.3.3.c … Critical Factors

46d. 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
C) Areas where acid vapors are present
D) All of the above are correct

Ans: D … API 571, Para. 4.3.3.5.a  Corrosion under Insulation … Appearance or MOD

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
D) None of these are correct

Answer = C … See Paragraph 4.3.3.7.a (Prevention)

21
 DM # 47 … ATMOSPHERIC CORROSION
47a. Which statement is FALSE regarding atmospheric corrosion?

A) Marine environments are the most severe

B) Dry rural environments cause very little corrosion.
C) It’s a form of corrosion that occurs from moisture associated with CUI
D) Moist polluted industrial environments with airborne contaminants are also the most severe

Answer: C … API 571, Para. 4.3.2.1 – Atmospheric Corrosion  Description of Damage …

Moisture associated with ATMOSPHERE

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 occur

B) Susceptible to conditions that cause increased corrosion rates
C) Susceptible to conditions that cause decreased corrosion rates
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

22
 DM # 50 … BOILER WATER COND. CORR.
50a. The common 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

Answer = A … See Para. 4.3.5.7 (Inspection & Monitoring)

4.3.5.3 Critical Factors

a) Corrosion in boiler feedwater and condensate return systems is usually the result of dissolved gases,
oxygen and carbon dioxide.

b) Critical factors are the concentration of dissolved gas (oxygen and carbon dioxide), pH,
temperature, quality of the feedwater and the specific feedwater treating system.

c) Corrosion protection in the boiler is accomplished by laying down and continuously maintaining a
layer of protective Fe3O4 (magnetite).

4.3.5.5 Appearance or Morphology of Damage

a) Corrosion from oxygen tends to be a pitting type damage and can show up anywhere in the system
even if only very small quantities break through the scavenging treatment. Oxygen is particularly
aggressive in equipment such as closed heaters/economizers where there is a rapid water temperature rise.
b) Corrosion in the condensate return system tends to be due to carbon dioxide although some oxygen
pitting problems can occur if the oxygen scavenging treatment is not working correctly. Carbon dioxide
corrosion tends to be a smooth grooving of the pipe wall.

4.3.5.7 Inspection and Monitoring

a) Water analysis is the common monitoring tool used to assure that the various treatment systems are
performing in a satisfactory manner. 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 proactive 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.
c) Deaerator cracking problems can be evaluated off-line at shutdowns (use proper WFMPT methods).

23
 DM # 51 … MICROBIOLOGICALLY INDUCED CORR
51a … 4.3.8.1 Description of Damage

A form of corrosion caused by living organisms such as bacteria, algae or fungi. It is often
associated with the presence of tubercles or slimy organic substances.

51b. 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
D) None of these are correct

Answer: A … API 571, Par. 4.3.8.3.a  MIC … Critical Factors

51c. 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) Microbiologically Induced Corrosion

B) Boiler water condensate corrosion
C) Sour water corrosion
D) Cooling water corrosion

Answer: A … Reference: 4.3.8.3.a  MIC … Critical Factors

51d. 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

Answer: D … Reference: 4.3.8.3.d … Critical Factors

24
 DM # 51 … MICROBIOLOGICALLY INDUCED CORR
51e …4.3.8.5 Appearance or Morphology of Damage

a) MIC corrosion is usually observed as localized pitting under deposits or tubercles that
shield the organisms.

51f …4.3.8.5 Appearance or Morphology of Damage

b) Damage is often characterized by cup-shaped pits within pits in carbon steel or

subsurface cavities in stainless steel (Figure 4-45 through Figure 4-50). HALO EFFECT

51g. 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
C) Ozone and ultraviolet light
D) Biocides (such as chlorine, bromine)

Answer: A … API 571, Para. 4.3.8.6.a  MIC … Prevention/Mitigation

51h. 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 571, Para. 4.3.8.7.a/b  MIC … Inspection & Monitoring

25
DM # 53 … GALVANIC CORROSION
Galvanic Series Table below (See page 4-103)

26
 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) Small anode to cathode ratio B) Large anode to cathode ratio

C) Small cathode to anode ratio D) Large cathode to anode ratio

Answer: B … 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) None of these

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

27
 EXERCISE 53 … GALVANIC CORROSION (8 Qs)
4. For galvanic corrosion to occur, which of the following items is NOT REQUIRED?

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 … (Appearance 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)

28
 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
D) None of these are correct

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

29
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

30
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

31
 DM # 58 … SOIL CORROSION  10 Q&A
58a. 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 … 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

Answer: A … API 571, 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) Cathodic 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 + 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

Answer: D … API 571, Para. 4.3.9.3.c – 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 Corrosion (Critical Factors)

32
 DM # 58 … SOIL CORROSION  10 Q&A
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

Answer: 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

Answer: 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) 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

Answer: B … Ref: 4.3.9.7.a  Soil Corrosion (Inspection and Monitoring)

58j. Regarding soil corrosion, CP should be performed and monitored in accordance with:

A) NACE RP0169
B) NACE RP0472
C) The owner user’s standard
D) None of these

Answer: A … Ref: 4.3.9.7.a  Soil Corrosion (Inspection and Monitoring)

33
 OLD Q&A FOR API 570 EXAM (16 DMS OF API 571 & API 574 Points)

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)

34
 API 570 EXAM (16 DMS OF API 571 & API 574 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
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

35
 API 570 EXAM (16 DMS OF API 571 & API 574 Points)  API 570, PARA. 5.4.1.3
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
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 = A … 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
D) None of these are correct
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

36
 API 570 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 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
D) None of these are correct
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
D) None of these are correct
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”

37
 API 570 EXAM (16 DMS OF API 571 & API 574 Points)  API 570, PARA. 5.4.1.3
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 Corrosion 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

38
 API 570 EXAM (16 DMS OF API 571 & API 574 Points)  API 570, PARA. 5.4.1.3
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
D) None of these are correct
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
D) None of these are correct
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

39
 API 570 EXAM (16 DMS OF API 571 & API 574 Points)  API 570, PARA. 5.4.1.3

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
D) None of these are correct
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
D) None of these 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
the:

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 the air) at the 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

40
 API 570 EXAM (16 DMS OF API 571 & API 574 Points)  API 570, PARA. 5.4.1.3

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

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

41
 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

574 Environmental Cracking points to prepare for API 570 exam

b) Polythionic acid SCC of sensitized austenitic alloy steels resulting from exposure to
sulfide/moisture condensation/oxygen.
c) Caustic SCC (sometimes known as caustic embrittlement).
d) Amine SCC in nonstress-relieved piping systems.
e) Carbonate SCC in alkaline systems.
f) Wet hydrogen sulfide stress cracking and hydrogen blistering in systems containing sour
water.
g) Hydrogen blistering and hydrogen induced cracking (HIC) damage. This has not been as
serious of a problem for piping as it has been for pressure vessels. It is listed here because it is
considered to be environmental cracking and can occur in piping although it has not been
extensive. One exception where this type of damage has been a problem is longitudinally-welded
pipe fabricated from plate materials.

See API 571 for additional details on environmental cracking mechanisms.

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

42