Caustic Corrosion: 1. Localized corrosion due to the concentration of caustic or alkaline salts that usually occurs under evaporative or high beat transfer conditions is called: A) Alkaline Sour Water Corrosion B) Caustic Corrosion C) HCL Corrosion D)} None of these 2. Carbon steel and 300 Series SS have serious corrosion problems in high strength eaustis Solutions above about: AA 15°F (66°C) JB) IIS*F (79°C) * C) 20°F (93°C) D) None of these are correct Page $ of 11 Scanned by TapScanner gre 3. Which materials given below are the least susceptible to caustic cor wel BY Low Alloy steels ©) Contain orades af stabulined 300 Serica SS yo? D) Nickel based allayte oe rrwear igs See Para. 4.3.30. _.. Caustic Corrosion ... Description of Damage A 2.8... See Para. 43.10.60... Coustic Corr .. Prev ion Mitigation) 9 3.0... Refi4.3.10.2 &4.3.i06.c... ... Caustic Cor ... Affected Materials & PM4.3.10 Caustic Co ic corrosion? Which of the following materials are not affected by caustic cor a. Carbon steel! b. Lowalloy steel c. 400 senes ss ¢. 300 senes ss Caustic corrosion is most often associated with: Nuclear plants Boilers and steam generating Oil and gas Petro chemical 2 a b “i qd ustic corrosion is characterized by, @ Uniform corrosion b. Pats c. Grooves <. Cracks Caustic corrosion is best prevented by. a. Proper design b. Upgrading material ¢ Heat treatment ¢ All of the above Caustic corrosion is the problem in high strength caustic solutions above: 2 0 °F b S00'F c 150°F ¢. Room temperature Which of the following material is resistant to Caustic corrosion? @. 300 series ss b. Low allay steel ©. Alloy 400 Duplex ss Localized ion due to the concentration of that usually occurs under €vaporative condition: @ Carbonate corrosion ». Caustic corrosion ¢ Alkaline corrosion d None of the above caustic or alkaline salts sis__. -_ ce co he ee SB Ba Rh TR OA~ 4.3.10 CAUSTIC CORROSION Qno 1 2 3 4 uw“ ~~ oOi 4.3.10 Caustic Corrosion. 4. General corrosion from caustic or alkaline salts can occur depending on its: 2. point of entry into the system. b. percentage of oxygen in the solution. . solution strength. ¢. date of manufacture. 2. Pick the metal below that would be most affected by caustic corrosion. a. Monel. b, Inconel. . Titanium. d. Carbon steel. 3. Caustic is often found in hydrocarbons in AST's because: a. itis 2 good corrosion inhibitor. bit is sometimes added to process streams for neutralization. it adds to the octane rating of gesoline. |. it promotes the lubricating nature of oils. 4. Alkaline salts may also enter process streams (and thus into tanks) through in condensers or heat exchangers. instrument connections injection points c, addition d. leaks 5. Caustic solutions many times ere used to remove from process streams. a. solubles b. water c. amine compounds d. sulfur compounds 6. Caustic may become concentrated by departure from . evaporation and deposition a DEA b. HIC c. DNB d. FMR: 7.An inspector is checking @ tank that contains water bottoms and a hydrocarbon product that has been neutralized by using caustic, He suspects there may be caustic corrosion, Where would be a likely place for this to occur? 2. It probably would occur elong @ weterline (possibly the interfece water to hydrocarbon). b. It would most likely occur in the vapor space of the tank. ~~ ¢. He should look at the tank floor near the inlet line to the tank. d. He should check the tank shell opposite the inlet line to the tank.Caustic CorrosionCaustic Stress Corrosion Cracking (Caustic Embrittlement): a 1,,Caustic embrittlement is a form of stress corrosion crack initiated cracks in piping and equipment exposed to caustic and located: g characterized by Surface- ( A) In the HAZ of welds always B) Most often in the HAZ of welds ) Mostly adjacent to Non-PWHT welds D) Mostly adjacent to zones of high stress CAewate embrittlement cracking can be effectively prevented by means of PWHT ata temperature of: A) 1100° F (593°C) (5) 1150° F (621°C) C) 1200° F (649°C) D) 1250° F (677°C) Page 7 of 11 Scanned by TapScanr 3,/Hlow can Caustic Stres A an Caustic Stress Corrosion Cracking be prevented on Non-PWHI'd CS lis A) Uparade io 300 Series SS de to the nickel steamout cleaning D) None of th Cs Ren Which of these actions are required fur a piping system with a 30% Caustic Sulutio operating at 140°F (OPEN BOOK QUESTION REPORTED)? re A) Use Nickel a!Caustic Stress Corrosion Cracking (Caustic Embrittlement): 1.C... See Para, 4.5.3.1 ... CAUSTIC SCC > Description oF Damage . Prev/Mit > NACE SP0403 not requires a 1175 +25 F 3.C.... See Para, $.5.3.6.4 ... Caustic SCC > PreventionMitigation 4.3... 571 Pare. 4.3.3.3.b & Fig 4-146 > Caustic Embrittle4.8.3 Caustic Stress Corrosion Cra (Caustic Embrittlemen 4. Caustic embrittlement is 2 form of characterized by surtace-initicted cracks that ocour in piping and equipment exposed to caustie, primarily adjacent non-PWHT'd welds. 8. galvanic cracking b. Stress corrosion eracking Chloride cracking 4. fetigue cracking 2. Primarily, where would you inspect for ceustic embrittiement (caustic stress corrosion cracking)? a, Examine the piping externally in long streight runs. b. Look af areas covered by insulation, . Check the piping internally, away from welds. =) Inspect next to non-PWHT'd welds. ~~ 3. What materials are affected by caustic embrittlement? ‘a. Monel and Inconel are susceptible to caustic embrittiement. | ——-— b Carbon stee! and 300 series SS are susceptible to caustic embrittlement. ¢. Titanium and Nickel 200 are susceptible to ceustic embrittlement. @. incoloy and Nickel alloys are susceptible to ceustic embrittlement. 4: In caustic embrittlement, what two conditions, if changed, will promote more severe cracking? ‘@ Change the location from inside to outside and decrease the temperature. b, Deoresse the temperature and the caustic concentration. ¢. Increase the temperature and the caustic concentretion. @, Subject the equipment to more exposure to weter and increase the stress level ff 5! Ceustic stress corrosion or caustic embrittlement typicelly propagates to the weld in adjacent , ? base metal but can also occur in the weld deposit or heat affected zones. a. perpenciular », parallel ¢. vertical 4. at 2 90 degree angle COPYRIGHT © 2007-J. W. COLEY & CODEWEST-ALL RIGHTS RESERVED-DO NOT COPY WITHOUT PERMISSION 50 REVIEW OF API RP 574, FIRST EDITION, DECEMBER 2003-SUPPLEMENTAL CERTIFICATION TEST COPYRIGHT 8 2007.) W. COLFY & CODEWEST-ALL RIGHTS RESERVED-DO NOT COPY WITHOUT PERMISSION — 6 post weld heat treatment fo stress relieve the eouipment can help effectively in preventing caustic J © Smbtitiemert cacking of carbon steel. What temperature should be used for PWHT? a. 650°F. b, 1550°F, 6. 15°F. . 1450°F7. An ingpector calls for low pressure steam out of equipment that has contained caustic in preparation for ‘weld repairs. The inspector requires that the equipment be washed thoroughly with clean water prior to steam ‘oul. What does this prevent? 2. Amnine stress corrosion cracking b. Ghlorde cracking ¢ Caustic embaitlerent cracking. 34. Carbolc acié environmental cracking 8. What method NDE is not effective for finding caustic embrittlement cracking wrien itis tight & scale-filed? aeee §554 MT 9, What are two other similar forms of alkaline stress corrosian cracking mechanisms? “> at Amine and carbonate cracking. ) b-Hydrogen and peroxide cracking. 7": Hyperchiorite and oxalic acid cracking 4. Formic acid ard glycerin cracking, +10, What maximum temperature of 50% by weigh! concentration of caustic can you operate carbon steel equipment without stress relieving t rewaeet a About 20°F b. About 180°F About 128°F About 17°F “11, How do yeu inspect for caustic embrittlement? 4. Cracks may be seen visually but crack detection is best performed with WFMT, ET, RT, or ACFM, Usually ‘surface preparation is required by afit or high pressure water blasting, b. Creeks ore not detectable visually so as 2 minimum the surface must be chemically cleaned end polished | preparation for replication for eboretory testing. PT ie sometimes also etfectve. c. Cracks are eesiy cetecied using veval Inspection oF PT. Litle or no surface preparation is required. Light clesning pror to using the dye peneirent is al that is necessary. 4. Cracks are east celected using visuel inspection; however, minor manual cleening of the surface in ‘question expedite the inspection. Vi. COLEY & CODEWEST-ALL RIGHTS RESERVE 4 .20 NOT COPY WITHOUT PERIISSION REVIEW OF API RP 574, FIRST EDITION, DECEMBER 2003-SUPPLEMENTAL CERTIFICATION TEST MEW Or are 2ob7-2. Wi COLEY & CODEWEST-ALL RIGHTS RESERVEO-DO NOT COPY WITHOUT PERMISSION ) ‘2, What equipment ie ffecied by casticstess cortosion cracking? ‘a Couetic cracking is cfien found in equipment on Mult catalytic cracking units thet is used to hold or transport the calalyst used in the processing of gas ol : b. Ceastc otscking Is cfien ound in equipment that handles caustic, including H.S and mercapten removal unite, ¢ wel 2s equipment that neuialzes 2cid in H,SO, and HF units. c. Canatc cracking ig offen found in equipment on Furfurel handing units and in units processing rmotor ois thot use N-Methyt-Pyrraidon which promotes caustic cracking. 4. Calete cracking is cffen found in equipment on continuous catalytic refining units CCR's, Cracks ave formed from the "caustic Ike" catalyst used on these units,Caustic SCC 4 b, 4.5.3.1 d, 4.8.3.1 3. |b, 4.5.3.2 | 4 | cc, 4.5.3.3¢b | 5 | b, 4.5.3.5(a | 6 | c, 4.5.3.6(a 7 c, 4.5.3.6(d 8 c, 4.5.3.7{b ee: 10 | d, Tab 4-85 1 11 | a, 4.5.3.7 | 312-| b, 4.5.3.4Embrittlement 4.5.3 C: Stress Corrosion Crackin Caus' 4. Caustic SCC occur in piping and equipment exposed to caustic primarly: a. In carbon steel only b. Adjacent to non Pwht'd welds c. Heat affected zone d. All of the above 2. Which of the following materials is more resistant to caustic SCC? a. Nickel base alloys b. Chromium base alloys c. Molybdenum based alloys d. 300 series SS‘At what caustic concentration caustic SCC occurs when concentrating mechanism is present? Less than 100 ppm a b. 110 20ppm cc. 50to 100 ppm d. 250 to 500 ppm caustic SCC PWHT should be carried out at: a. 1200 °F b. 1150°F c. 1100°F ¢. 1000°F To prevent caustic SCC before steam out, equipment should be: a. Heat treated b. Water weshed c Acid cleaned d. Sand blasted To prevent Caustic SCC detection is best performed with WFMT,EC,RT or: a UT b. Phased array ET c. ACFM d. PT Which of the following surface preparati i paration methods pi dean are used for caustic e water blasting4.5.3 CAUSTIC EMBRTTLEMENT QNO ANS 1 | B 2 A 3 | c 4 | 8B 5 B 6 c 7 DAmin Stress Corrosion Cracking: I. Which of these materials is not susceptible to amine cracking? A) Carbon steels B) Low alloy steels B) Both CS & LA Steels FyBoth 300 & 400 Series SS 2. Amine stress corrosion cracking is most often associated with lean amine service aud pure alkanolamine does not cause cracking. Rich amine service cracking is most often associated with which of the following? A)H'S By Wet PS C) Stress D) TemperatureAmin Stress Corrosion Cracking: 1D... Refi 5.1.2.2.Le&$ 1.2.2.2 ... Amine SCC D of D & Affected Materials . 2B... Reference: $.1.2.2.3.¢ ... ... Amire SCC > Critical Factors5.1.2.2 Amine Stress Corrosion Cracking 4. Which of the following materials are not affected by amine SCC? 2 Carbon stee! 5 Low alloy stee! 00 senes SS c All of the above 2. Amine SCC is often associated with: @ Rich amine services b Lean amine service c Caustic concentration d None of the above 3. Amine SCC crack detection is best performed with ACFM or: VIF MT UT RT PT aoco4, Amine cracking initiate on the: a. ID of piping b. OD of piping c. Midwall thickness of piping d. None of the above 5. Amine cracking is a form of. stress corrosion cracking. a. Hydrogen b. Caustic c. Polythionic 4. Alkaline 6. Amine stress corrosion cracking is most often associated with lean amine services. The pure alkanolamine does not cause cracking. Cracking in rich amine services are most often associated with_problems. a. HS b. Stress c. Wet HS. d. Temperature. 7. Amine SCC can be prevented through: a. PWHT. b. Use clad SS or alloy 400 c. Water wash non pwht'd piping before welding 4. All of the above 8. Which of the following NDT is usually not effective in finding tight and/or scale filled cracks and should not be used a. WFMT. b. ACFM. c. PT. d. All of the above. 9. Surface preparation required for WFMT is: a. Grit blasting, b. high pressure water blasting c. sand blasting d. A&B of the above— | OSION CRACKIN 2 AMINE STRESS CORR “QNo | B A A D ¢ D cr 2Amine Corrosion Cracki 4. Amine cracking is a form of a, hydrogen attack. b, escorbic stress corrosion cracking. ¢. acidic stress corrosion cracking. d. alkaline (caustic) stress corrosion cracking. 2. In carbon steel piping, where would you expect to find amine stress corrosion cracking? a, Itis usually found in weld ells where piping changes direction. b. itis most often found at or adjacent to non-PWHT'd welds. ¢. itis commonly found in piping dead legs. 4. It may be found at breaks in insulation where moisture is trapped. 3, Three aritical factors in causing emine stress corrosion cracking are amine concentration, and temperatures. ‘a, amount of compressive force b. age of the material ¢. level of tensile stress 208. amount of vibration ./Amine cracking is most often essociated with: a. rich amine service. b. caustic content in the product. . lean amine service. 7 4d. acidic content present. ALY 5, What is 2 good way to mitigate emine stress corrosion cracking iri carbon steel piping? a. Peen the welds. b. Use a high nickel weld rod to make the welds in the carbon steel. «. Pre-heat all carbon steel welds. d. Post weld heat treat all cerbon steel welds. 6. What API document covers the problems of amine stress corrosion cracking? a. APLRP 1107 b. APIRP 575 - ¢, API RP 874 4. APIRP 945 5.1.2.3 Wet H2S Damace (Blisterina/HIC/SOHIC/SCC).| Amine Stress 2 1b,51.22.10) 3. | oc, 5.1.2.2.3{a) 4 | c, 5.1.2.2.3(e) 5 | d,5.1.2.2.6(a) 6 i d, 5.1.2.2.6(awp soysen Chloride Stress,Cracking (Cl-SCC): Gen of the following materials is susceptible to Chloride SCC? A) Carbon steel B) 300 Series SS C) Low alloy stee! D) 400 Series SS QDentoride SCC usually occurs above what metal temperature and pH value? A) Above 125° F (52°C) and pH 3.0 5) 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 i What are the preferred methods of detecting Chloride SCC? A) PT only B) PT or WEMPT ©) PT or Phase Analysis EC techniques D) UT shearwave and RT, because PT cannot locate extremely fine cracksChloride Stress Corrasion ing (CLSCC): 1B... Ref 4.5.1.1 &45.1.3.L ... Ciiloride SCC > D of damage & Critica! Factors B ... Ref.4.5.1.3.g’ ... Chloride SCC > Critical Factors 4.5.1.7.5 > Chloride SCC > Inspection & Monitozizg4.5.4 Chloride Stress Corrosion Cracking (CI-SCC) 4. Which of the following materials are highly susceptible to chloride Scc? Carbon steel Low alloy steel 300 series SS. All of the above o aoc 2. Chloride SCC usually occurs at metal temperature above: 300°F 140°F aove aa na 6 ho 3. Chloride SCC usually occurs at PH values: a. ito7 b. Less than 2 c. Above Z d. None of the above 4. The greatest susceptibility for chloride SCC is at nickel content of: a. 8% to 12% b. Above 35% c. Above 45% d. None of the above5. Above 45% nickel content the chloride SCC possibility are: a. Greatest possibility b. Highly resistant c. Nearly immune d. None of the above 6. Which of the following NDT methods are preferred to detect chloride SCC? a. PT and phased analysis eT b. PT and UT c. PT and RT d. WFMT and UT 7. which of the following surface preparation method is used for the detection of extreme fine cracks: a. Grid blasting b. High pressure water blast c. Grinding d. Sand blasting 8. 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 co?4.5.1 CI-SCC ANS QNO Ulma|uU\/aq) Uj; ati aa Sani mM st Mm woe! o9. 009 pray 4. Chloride Stress Corrosion Cracking (CLSCC). 4. Chloride stress corrosion cracking (CLSCC) is surface initieted cracks found in: a. carbon steel. b. low chrome alloy steel. c. 300 series SS and some nickel base alloys. d. nickel base alloys. 2. Thé CLSCC surface cracks appear under the action of , temperature and an aqueous chloride environment. a. stagnant conditions bi high velocity products c. compressive stress. d. tensile stress 3, The presence of what other element increases the propensity for Cl SCC cracking? a. Carbon dioxide. b, Oxygen. c. Carbon monoxide. d. Nitrogen. 4. What percent of chlorides is safe for exposure to 300 series stainless steel? a. 15% b. 10% c.5% d. 0% “5, SCC usually occurs at pH values above: aoro Dena“) 6. Stress corrosion crecking usually occurs at metal temperatures ebove about: a. 200°F. b. 160° F. ©. 140° F. 6. 100° F. 7. Nickel content of an elloy above percent makes it highly resistant to SCC. a.10 b.25 35 4.15 8. What kind of steel is not susceptible to SCC? a. AISI Type 347 SS. ! b. AISI Type 316 SS. c. Carbon steel. d. Duplex SS. 9. Characteristic stress corrosion cracks have: a. a generally random patiern and they do not join together. | bi lightning bolt appearance and are usualy singular in nature. \, e: many branches and may be visual detectable bya craze-cracked appearance i J d. few branches and are not visually detectable. ~7 40. aninspector is preparing to hydrotest equipment that is made from AISI Type 304 stainless steel. One of | the more important items that should be used is the: a, use of low oxygen content test water. use of low or no chloride weter and dry out thoroughly and quickly. c. type of device to be used to pressure the system. 1d. kind of chemical to be placed in the water to retard effects of chlorides. 44. Whatis one of the preferred methods for finding SCC? wth b. RT. © AE. @. PT. 4.5.2 Corrosion Fatique./ NO. | ANS. PARAGRAPH ! | Chloride SCC [ 4, 4.5.1.7(b)Cooling Water Corrosion: 1. General or loc salts, gases, of ized corrosion of carbou stee!s and other met s caused by dissolved nic compounds or microbiological activities is called 2. Cooling water corrosion is closely related to and should be considered together witb: A) Stress R) Velocity ©) Fouling D) Erosion QQw performance measurement (information an scaliug and fouling) can be done by: A) Monitoring biocides & biological activity B) Measuring pH and oxygen content <) Periodie calculation of U-factors D) Monitoring CW outlet tempsCooling Water Corrosion » Ref 4.2.4.1 Cooting Water Corrosion ... Descri ve LIS 46°C) > Salt water scaling 2.0... Rei 4343.2... Critical Feetors 3.C.., Refi 43.4.7.afb ... Insp & Monitoring1. d. Allot the above: 4.3.4 Cooling Water Corrosion Which of the following will result in scaling potential in fresh water? a. Above 115°F b. Above 140 °F c. Above 250°F d. Between 212°F to 350°F Which of the following fluid velocities will result in fouling ? a. Above 3FPS b. Below 3FPS. c. Above 5 FPS d. None of the above How cooling water corrosion will appear in ERW pipes? a. Pitting b. Localized corrosion ¢. Grooving d. Cracking General or localized corrosion of carbon steels and other metals caused by dissolved salts, gases, organic compounds or microbiological activity is called a. Cooling water corrosion b. Oxidation c. MIC d. None of the above. Cooling water corrosion and___ are closely related and should be considered together. a Stress b. Velocity c Fouling d. Erosion6. Cooling water corrosion can result in many different forms of damage including general corrosion, pitting corrosion, , Stress corrosion cracking and fouling a MIC b HIC ¢ SOHIC d. All of the above 7. With very few exceptions, cooling water should always be on the side to minimize stagnant areas. Tube Shelli aocm 8 Which of the following materials will affected by cooling water corrosion? Carbon stee! Titanium and nickel base alloys. 300 series SS all of the above eo0MANS QNO 4.3.4 COOLING WATER CORROSIONAtmospheric Corrosion: 1, Which statement is FALSE regarding atmospheric corrosion? A} Menine environments are the mast severe B) Dry rural environments cause very litte corrosion C) it's a form of corrosion that occurs from motsture assaciated with CUL D) Moist poliuted industrial sats with airborne contarmmants are also the most severe mospheric Corrosion rates vary greath duc to a variety of factors (see question with the temperature up to about 250°F (121°C). At hic equipnicat surfaces are: above). Corrosion rates incre temperatures above 250°F 121°C A) Usually too dirs foro B) Suscepnble i C) Susceptible te condatrons tha Di Usually tee dn tf at nyt n rates ulation (that ean remain wetted)sox corrasi -C., APL S71, Pera. 4.3.2.1 — Atmospheric Coxrasion > Description of Damage. Moiscure associated with ATMOSPHERE -— Atmospheric Corrasion Question 2D... API S71, Para. 4.32.4.3.2 Atmospheric Corrosion 4. Which of the flowing will have most severe atmospheric corrosion? a. Wet rural areas b. Dry rural areas ¢. Marine environment and moist polluted industrial environment d. All of the above 2, The corrosion rate of marine environment will be: a Less than 1 mpy b 5to 10 mpy c. 20 mpy d 1-3 mpyWhich of the following temperature will have high atmospheric corrosion? a 350°F b.250°F ©. 100°F d 20°F The best prevention for atmospheric corrosion is ? a Cathodic protection and surface preparation b. Cathodic protection and coating application cc. Surface preparation and proper coating application Change in atmospheric conditions. Atmospheric corrosion: a Can cause either uniform or localized wall loss b Always causes localized wall loss. ¢ Always causes uniform wallloss ¢. Is best detected using profile RT. 6. Which of the following materials is least affected by atmospheric corrosion? a Carbon ste! b. Chromes c. Stainiess steels d. Copper alioyed with aluminum. 7. 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 0. Cooling Water Corrosion Atmospheric Corrosion rates vary greatly due to a variety of factors (see question above). Corrosion rates increase with the ternperature 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 rales ¢ Usually too dry for corrosion to occur 4. Usually too dry for corrosion to occur. except under insulation PF COAOQAHAAKAAEAA4.3.2 ATMOSPHERIC CORROSION QNO ANS 1 Cc 2 c 3 B / 4 c S A 6 c 7 A 8 5: 4.3.2 Atmospheric Corrosion, 4, Inwhet type of environment would atmospheric corrosion be most severe? ‘2, Marine environments, and moist polluted industrial environments, b Desert environmenis, and cold dry rural environments. ‘0, Ares exposed 10 the morning sun and prevailing winds. ¢. Fer north environments with meximum exposure to cold and snow. 2, What materials ate stfected most by atmospheric corrosion? a. Nickel 200, Inconel, and Incoloy. '. Monel, Ttanium, Durenickel eloy 301. €.300 series siainlees stesis and castro. & Carbon steal, low aly steels, and copper aioyed aluminum COFYRIGHT ©7007). W. COLEY & CODEWEST-ALL RIGHTS RESERVED-DO NOT COPY WITHOUT PERMISSION 24 REVIEW OF API RP 671, FIRST EDITION, DECEMBER 2003-SUPPLEMENTAL CERTIFICATION TEST Me oe it 20074. W.COLEY & CODEWEST.ALL RIGHTS RESERVED-DO NOT COPY WITHOUT PERMISSION Js, ra bere carton steel in is lceted next 102 cooling tower with mist rom the fower on the ine, whiat would ett expect to happen ine le sony protected by alurinum paint? 2. Severe extemal oxidation due to etmospheric conditions. The paint wil protect the ine and no corrosion will occur. ©. Minor almospneric corrosion could be expected. & Nothing wil happen. The coneitions for corrosion are not present 4 How many mis per year would you expect a carbon steal Ine to lose exposed to @ marine environment? a. 20mpy b. 1 mpy c 10mpy d, Spy 6, Whet is the atmospheric corrosion rate if carbon steel is exposed in a dry rural environment? 8. Lees than 4 mpy b. Less than 3 mpy c. Less then 2 mpy 6, Less than 1 mpy :ln etmospherié corrosion, what naturally eceurring substance, I gels on equipment, will cause accelerated ‘corrosion and stains? a. Rain b. Bird feces, ©, Snow, 4. Dust “7. What can prevent atmospheric corrosion? a. Build plants in dry rutet areas. 5. Surface preparation and proper coatings applted correctly. c. Use stainless ete! equipment. 4. Cost all surfaces exposed to the etmosphere with automobile undercoating. ‘8 What inepeetion methods are used for inspection and monitoring atmospheric corrosion? 3. AE and RT b, PT and WENT GET and MT VT end UT 43.3 Corrosion Under insulation (CUI: 4.3.2 Atmospheric Corrosion, 4, Inwhet type of environment would atmospheric corrosion be most severe? ‘2, Marine environments, and moist polluted industrial environments, b Desert environmenis, and cold dry rural environments. ‘0, Ares exposed 10 the morning sun and prevailing winds. ¢. Fer north environments with meximum exposure to cold and snow. 2, What materials ate stfected most by atmospheric corrosion? a. Nickel 200, Inconel, and Incoloy. '. Monel, Ttanium, Durenickel eloy 301. €.300 series siainlees stesis and castro. & Carbon steal, low aly steels, and copper aioyed aluminum COFYRIGHT ©7007). W. COLEY & CODEWEST-ALL RIGHTS RESERVED-DO NOT COPY WITHOUT PERMISSION 24 REVIEW OF API RP 671, FIRST EDITION, DECEMBER 2003-SUPPLEMENTAL CERTIFICATION TEST Me oe it 20074. W.COLEY & CODEWEST.ALL RIGHTS RESERVED-DO NOT COPY WITHOUT PERMISSION Js, ra bere carton steel in is lceted next 102 cooling tower with mist rom the fower on the ine, whiat would ett expect to happen ine le sony protected by alurinum paint? 2. Severe extemal oxidation due to etmospheric conditions. The paint wil protect the ine and no corrosion will occur. ©. Minor almospneric corrosion could be expected. & Nothing wil happen. The coneitions for corrosion are not present 4 How many mis per year would you expect a carbon steal Ine to lose exposed to @ marine environment? a. 20mpy b. 1 mpy c 10mpy d, Spy 6, Whet is the atmospheric corrosion rate if carbon steel is exposed in a dry rural environment? 8. Lees than 4 mpy b. Less than 3 mpy c. Less then 2 mpy 6, Less than 1 mpy :ln etmospherié corrosion, what naturally eceurring substance, I gels on equipment, will cause accelerated ‘corrosion and stains? a. Rain b. Bird feces, ©, Snow, 4. Dust “7. What can prevent atmospheric corrosion? a. Build plants in dry rutet areas. 5. Surface preparation and proper coatings applted correctly. c. Use stainless ete! equipment. 4. Cost all surfaces exposed to the etmosphere with automobile undercoating. ‘8 What inepeetion methods are used for inspection and monitoring atmospheric corrosion? 3. AE and RT b, PT and WENT GET and MT VT end UT 43.3 Corrosion Under insulation (CUIl Atmespheric Corrosion | 4 | 4, 4.3.2.1 2 | 6, 4.3.2.2 3 4,4.3.2.3{a { 4 Le. 50) § 6 t 1 m a. >|ur Water Corrosion (Acitic): —- of sivel due to Acidic Sour Wator containing FPS tends to occur at: A) pH >7 B) pH >2 O\pH>3 ib) pH>4.s 40 7.0 2. Which of these choices include all critical factors for Sonr Water (acidic) carrosian A) H2S content, pH, temperature, velocity and oxygen concentration 5B) ES content, pH, temperature and oxygen conceatration C) HGS content, pH, temperawre D) None of theseSour Water Corrosion (Acid: 1D... See Par. $.1.1.10.1 3 ... Sour Water (Acidic) Corr ... D: of Damage 2A... Refi 5.1.1.10.3.c Sour Water adic) Corrosion ... Critical Factorsour Water Corrosion (Acidic s corrosion of steel due to acid sour water containing 4. Sour water corrosi H2s at a PH between: a 1to7 b 45to7 c 35to7 d 1to45 2 Which of the following materials is susceptible to sour water corrosion? Carbon steel 300 Senes SS 400 Series SS Both B and C aocw 3. Sour water corrosion in. containing environments may be accompanied by carbonate SCC. HO HS co o 4, 300 Series SS can be used for sour water service at temperatures below "where Chloride SCC is not likely. © aoe 120° F 140° F 150° F 175° F aoe 5, Which of the following NDT method is used to detect sour water corrosion? a. Ultrasonic scanning b Profile RT ¢ UT thickness gauging oFEE5.1.1,10SOUR WATER CORROSION Qno i ANS veasiwn oenren\\ (0 Sour Water Corrosion (Acidic). | 4. Carbon stee! will corrode due to ecidic sour water containing HaS at a pH between | 4d. in low velocity areas woere ureters mie UrHy Unum @. 12,0 and 14.0 b. 4.5 and 7.0 | 7.0 and 9.0 ae 10.0 and 12.0 | i/} 2. which materia sted below is the legstesictant to sour water corrosion? i} a. 304 Stzinless Steel. 7 w ug ‘ b. Copper alloys. x 0 a ® c. Carbon steel. cu? a 4 d. 316 Stainless Steel. ds © 3. The presence of ___may increzse the corrosion due to sour water and thus it usually produces piting or underdeposit attacks. =) awater ) boir ~~ nitregen 4. silicon 4, The 300 series stainless steels may be used effectively to prevent sour weter corrosion if the temperature is less than: — 2. 30°F { b.250°F <6. 2420F, 6. 140°F 5. Sour water al 2 pH! above 4.5 can form s thick porous sulfide film over the surface of the metal containing it ‘When this happens what type of attack could ocour? 2. General thinning b. Groove type corrosion. «. Pitted type corrosion. d. Under deposit cracking. 544 44 Culfurin Arid Corrosion| Sour Water CorrosionHydrochloric Acidic(HCL) Corrosion: 1. Regarding Hydrochloric acid Corrosion, which of these are critical factors? A) HC] acid concentration, temperature and alloy composition B) HCl acid and water concentrations, temperature and alloy composition C) HCI acid and water and salt conceatrations, pH, temperature and alloy composition 1D) None of these are correct ‘id corrosion 2. Carbon steel and low alloy steels are subject to excessive hydrochloric when exposed to any concentration of HC) acid that produces a pH belo A)25 B)4.5 ©)55 D)7.0 3. Which materials have the best resistance against Hydrochloric Acid (HCI) Corrosion? A) Carbon steel and Low alloy Steels B) 300 series SS & 400 series SS C) Nickel-based alloys 1D) Copper Alloys 4. HCI 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5.1 Hydrochloric Acid (HCI Corrosion 4. Carbon steel and low alloy steels are subject to excessive hydrochloric acid corrosion when exposed to any concentration of HCI acid that produces a pH below. aoop AaaD aouo 2._____injection downstream of the desalter is another common method used to reduce the amount of HCI going overhead. a. Hydrogen b. Nitrogen c. Water d. Caustic. 3.Hydrochloric acid corrosion is most often associated with: a. Sulfidation. b. Oxidation. cc. MIC. d. Dew point corrosion. 4.Which of the following materials have good resistance to HCL corrosion: a. Carbon steel. b. 400 SS. c. 300 SS. d. Titanium and Nickel! base alloys. 5. HCL corrosion in 300 series appears as: a. Localized corrosion. b. Oxidation c Pitting d Chloride stress corrosion cracking 6. The rate and extent of damage due to HCL corrosion can be detected by: UT RT Strategically placed corrosion probes a b. c. d. None of the above.5.1.1.4 HCl ANS °° \ZioAinmetin CO) QqaQav,aiov wo5.1.1.4 Hydrochloric Acid Corrosion. 4. Damage in refineties from hydrochloric ccd is most atten aBsociated with cew point corresion in which vapors containing water and hydrogen chloride condense from the: 4. chaige ines from an atmospheric hese toa crude unit atmospheric dsttation tower. E overhead stream of 2 cletilaton, fractionation cr stipping tower on a catalytic refermer unit cc charge line to a reactor of a FCC unit ©. reflux streame of a vacuum tower on vacuum pipe stl. 12, Hyerochlorie acid corrosion affects which of the following refinery meteriale? ‘2. Carbon stee! b. Low alloy steel 400 seties SS 4. Alof the sbove 4, Carton steel and low alloy steels are subject fo excessive corrosion whan exposed to any concentration of "Hl acid that produces @ pH below about. 7 9.95 v.70 c.85 ds | 4. What type material has good resistance to dilute HCl ecid in many refinery epplications”? a mosieess 6, Titoniun pertorms well hn HCI service in oxidizing conditions but fells repisly in_ HCl service. a.wet brick c.dy 4. contamineted 16, An inepecter cheeke @ 300 series SS tne that has been subject fo HC! corrosion, What type of camage wouls the inspector find? 2. Ping or chloride stress corrosion cracking, ». General himing «. Localized thinning, 14. Deep groove type cosrosion. “COPYRIGHT © 2007 J.W. COLEY & CODEVEST-ALL RIGHTS RESERVED-DO NOT COPY WITHOUT PERMISSION 59 REVIEW OF API RP £71, FIRST EDITION, DECEMBER 2003-SUPPLEMENTAL CERTIFICATION TEST MN ent @ 26074. COLEY 6 CODEWEST-ALL RIGHTS RESERVED.DO NOT COPY WITHOUT PERMISSION 7. What does the damege liom HC! corrosion look Ike on cerbon steal matetiar? ) a. The damage usually eppears es arooving in the heat affected zones of welds. . The damage usually takes the form of rough deep piting The damage is usvaly inthe form of general binning but may be localzed nesr water phase condensing The damage takes the fom of random large deep pting, 8, How would you Inspect for lcaly thinned areas caused by HCI corrosion? a. AB and MT b.ET and PT ©, Automatic UT scans or profile RT a. WMT end AE 51.1.5 High Temp Hall. Corrosion 4.The presence of hydrogen in H,S streams increases the severity of high temperature sulfide corrosion atOOTP TD] | Pe 09 | Df et Hydrochloric Acid Corrosion _c, 5414.3(g a, 5.1.1.4.5(D C, 5.1.1.4.7(a c, 5.1.1.4.7 (¢API 571 STUDY GUIDE NN? Brittle F) fr" cture: 1. The sudden rapid fracture under stress (residual or applied) where the material exhib : pits little or no evidence of ductility or plastic deformation is called: AY S85° F Embritdement B) Texper Embritlement C) Stress Corrosion € 0) Britle Fracture cking ( % Which of these materials are NOT susceptible to britile fracture? A) Carbon steels B) Low Alloy steels C) 400 Series SS 19}300Series SS» 3. Regarding brittle fracture, when the critical combination of three factors is reached, brittle fracture can occur. Select the item that is NOT a ci ‘al factor for brittle fracture: A) Marcrial fracture toughness (resistance to crack like laws) as measured in Charpy impact test ©) Material tensile strength (resistance to crack like flaws) as measured in a tensile test C) Size, shape and stress concentration effect ofa flaw D} Amount of residual and applied stresses on the flaw o~ (A AMost cuses of Brittle Fracture occur only at: A) Temperatures above Charpy Impact wansition temperatures B) Charpy Impact temperatures have no relationship to Brittle Fracture oceurrences C) Temperatures below ambient and only in thick sections i) Temperatures below Charpy Impact transition temperatures Jain concern daring 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 1) Brittle fractureandl devoid of any associ ed plastic acks that are typically st deformation are likely associated with which type of failure? A} Chloride SCC B) Brittle fracture ©) Thennal fatigue 1) Stress Rupture 7. 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 8. 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 repaited/modified vessel in service when PWHT was not done B) Performing PWHT on a vessel if it was not originally done during manufacturing -€) Perform a “warm” pre-stress hydrotest followed by a lower temperature hydrotest D) Periodic inspections are to be performed at high stress locations €) Au Of Re AboveBrittle Fracture: 1D... 2D ans 3. Bass ri awe SD ayy CB Re& 4.2.7.3 > Brittle Fractar +- Deseription of Damage Refi 4.2.7.2... Affected Materials APIS71 ... Para. 4.2.7.3 ... Brittle Fracture ... Critical Factors See Paragraph 4. Ddelow > Critical Factors Ref. +.2.7.4.c/d > Britie Fracture ... Affected Units or Equipment Ref 4.2.7.5.0 & Fig 4-6 & 4-7 > Brittle Fracture ... Appearance or MOD APIS71 ... Para. 4.2.7.S.a ... Brittle Fracture ... Appeerance or morphology . .. See Paragraph 4.2.7.6. > Prevention/Mitisation Cd. None of the above. 4.2.7 Brittle Fracture 4. The sudden rapid fracture under stress without plastic deformation is called? a. Temper embrittlement b. Fatigue cracks c. Brittle fracture d. Ductile fracture Which of the following materials are not a. Carbon steel b. Austenitic stainless stee! c. Lowalloy steel d. 400 series SS affected by brittle fracture?Which of the following will increases the susceptibility of brittle fracture? a. Steel cleanliness b. Thick matenal ; c. Operating temperature below transition temperature d_ All of the above Brittle Fracture normally occurs at: a. Below room temperature b. Below transition temperature c. At high temperature d. None of the above Brittle fracture is best prevented by: a. Conducting PWHT b. Increasing operating temperature c. Using suitable materials for low temperature G. All of the above Which of the following NDT detect the possibility of Brittle fracture? a. PT b. RT c. UT d. NDT cannot detect possibility of Brittle Fracture Cracks that are typically straight, non-branching, and devoid of any associated plastic deformation are likely associated with which type of failure? a.Stress corrosion cracking b Brittle fracture c. Thermal fatigue. d. Temper embrittlement. Which of the following are found along the free edge of the fracture, or localized necking around the crack? a. shear lips. b. Intergranular craking. c. Necking d. None of the above.9. For new equipment, brittle fracture is best prevented by using: a. materials specifically designed for low temperature operation b. changing the design ©. changing the atmosphere. d. all of the above 10. Susceptible vessels should be inspected for pre-existing flaws/defects to detect the possibility of: a. brittle fracture b. atmospheric corrosion ce. CUL d. none of the above.4.2.7 BRITTLE FRACTURE QNO 1 26, Maruniess wor w+ 4d. Radiograph the materia question. 4.2.7 Brittle Fracture 4. Asudden repid fracture under stress (residual or applied) where the material exhibits ile or no evidence of ductilty of plastic deformation is called: ‘a. decarburization fracture. b. temper embrittlement. c. glass like failure. |. brittle fracture. ‘hnvee of the steeis listed below are susceptible to brittle fracture. Pick the one that is not. a, Carbon steel. b. 300 series of stainless steels. c. Low lioy steel. 4. 400 series of stainless steels i'3. Three factors when critically combined tend to cause brittle fracture. Which of the four factors listed below oes not belong? a. The material's fracture toughness (resistant to crack like flaws) is low. b. The size, shape end stress concentration of a flaw tends to lead to failure. . The temperature is high enough to induce failure. d. The amount of residual and applied stresses on the flaw is enough to cause fracture. 4, In most cases, brittle fracture occurs only at ternperatures below the Charpy impact temperature, the point at which the toughness of the material drops off sharply. a. failure b. transition c. critical d. stable &, What year did the ASME Boller and Pressure Vessel Code, Section VIll, Division 4 begin to require toughness as a criteria for vessels operating at cold temperatures? 2. 1987 b. 1942 ©. 1995 d. 1963 6. Brittle fracture can occur during ambient temperature during a hydro-test due to: a. unusual loading and high toughnéss at the testing temperature. b: high impact stresses and plasticity at the testing temperature. c. high stresses and low toughness at the testing temperature. d. high strength material and temperatures below 100 degrees F. 7. How do you mitigate brittle fracture of new equipment? a. Use only 400 series stainless steels. b. Use only 300 series stainless steels. ¢. Use material specifically designed for low temperature operation per ASME B&PV Code. __.. d. Use material designed for high temperature operation per ASME BBPV Code, ~ 8. \At what temperature does brittie fracture usual happen? a. Itonly occurs at temperatures between 400°F and 90°F. b. Itusually occurs at approximately 85°F. . Itoccurs only at ambient temperatures during shutdown, 4d. Itoccurs only at temperatures below the Charpy impact transition. 8. What mechanical inspection method may be used to detect the possibilty of brittle fracture of carbon, low alloy and 400 Series SS? 2. Replication’is a method that has had some success in detecting brittle trecture. bb. Inspection is not normally used to find brittle fracture. c, Checking the Brinnell hardness of the material should give en indication of brittle fracture. ¢. Shear wave ultrasonic testing will reveal minute cracks prior to the equipment failure.Brittle FractureErosion/Erosion-Corrosion: 1. 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: Ay Erosion B) Erosion-Corrosion C) Corrosion D) None of these 2. Metal loss that is the result of impact or abrasion (often removing protective films and scales) with contributing corrosion is called: A) Pitting B) Erosion C) Corrosion D Erosion’Corrosion5. In erosion’corresion, Corrosion contributes to erosion by: C A) Causing B) Causu ©) Causing abrasive wear TP, Removing protective films & scales 4. Crude and vacuum unit piping and vessels exposed to naphthenic acids in some crude may suffer which type of d temperature, veloci nage and severe metal loss when the specific factors of + and sulfur content are considered? A) Erosion @) Erosion-corrosion C) Erosion and erosion-corrosion D) NAC and erosion and erosion-corrosion AQ (3,Frosion and Erosion-Corrosion are characterized by: A) A localized loss in thickness due primarily to grooving B) General uniform wall loss or localized loss in the form of pitting or grooving <) A localized loss in thickness as pits, grooves, gullies, waves, rounded holes and valleys D) General uniform wall loss or localized loss as pits, grooves, gullies, waves, and rounded holes > 7 (6 Heat exchangers utilize which of these components to minimize erosion problems? A) Impingement plates, tube ferrules, horizontal baffles and pass pantition plates B) Impingement plates, tube ferrules, and horizontal baffles only ©) Impingement plates and tube ferrules only D) Impingement plates onlyErosion/Erosion-Corrosion: Aw 2D... 3. Dies .. AP] $71, Para. 4.2.14.4.¢ 3 Erosion Erosion-Cox API 571, Par. 4.2.14.1.2 > Exasiox/Esosion-Corrosion ... Desesiption of Damage ion of Damage See Para 4.2.14.1.2 > Erosion/Eresion-Corrosion ... Des See Para 4.2.14.1.a > Erosion 'Eiosion-Corzosion ... Description of Damage mn... Affected equipment _ API] $71, Para. £.2.14.5.a > Erosion/Eresion-Corrosion ... Appearance __ API 571, Par, 4.2.14.6 6 - Erosion Erosion-Corosion ... Affected equipment4.2.14 Erosion/Erosion — Corrosion 1.The accelerated mechanical removal of surface materials a result of relative movement between solid (Or)liquids is called as: a. Corrosion b. Erosion c. Erosion-corrosion d. None of the above 2. Erosion —-corrosion is a description for the damage that occurs when: a. Erosion contributes to corrosion by removing protective films b. Corrosion contributes to erosion by removing protective films c. Both of the above d. None of the above 3.Which of the following will not be affected by erosion and erosion corrosion? a. Elbows b. Downstream and blow valve c. Upstream of pumps d. Piping systems 4Which of the following is the characteristic appearance of erosion and erosion-corrosion? a. PITS,Grooves and vallys b. Holes and vallys c. Directional pattern d. Alll of the above.a y of mitigate erosion-corrosion? Which of the following is the best Wa! a. Changing Design b. Increasing surface hardness ¢. Changing material . All of the above gate erosion-corrosion? ing is the best way to miti Which of the followi tant alloy a. Using more corrosion resis' b. Altering process environment ¢ Increasing surface hardness ¢. Only a & b of above Refractory loss inside 2 vessel due to erosion can be detected by: a.UT b.IR c RT d. All of the above Pure erosion is very rare and is sometimes referred to as: a. Abrasive wear b. Undercutting c. Tiger striping d. None of these Improved resistance to erosion is usually achieved through: a increasing substrate hardness using harder alloys, hardfacing or surface- hardening teatments b. Using more corrosion resistant alloy c. Altenng process environment d. all of the above 40. which of the following material is not affected by erosion/ corrosion in sea water service.? a. monel b. 316 ss. c. titanium: d. brass4.2.14 EROSION/EROSION-CORROSION QNO | ANS 1 B — fe — 2 B i +} ———_———— 3 Cc —— | 4 | D 5 Cc 6 D 7 B t 8 A 9 A € 10¢. easy to tina by ragiogrepny. d. only a concem after a fire. 4.2.14 Erosion/Erosion-Corrosion 4. Accelerated mechanical removal of surface material 2s a result of relative movement between, or impact from solids, liquids, vapor or any combination thereof is known as: a. weathering b. corrosion. erosion. d. attrition. 2. A description of the damage that occurs when corrosion contributes to erosion by removing protective films or scales, or by exposing the metal surface to further corrosion under the combined action of erosion and corrosion is called: a. suriace weathering. b. erosion-attrition. c. erosion-corrosion. 4. abrasion-wear. 3, Equipment thet is exposed to moving fluids andior catalyst is subject to erosion and erosion-corrosion. ‘What unit is most often damages by gas borne catalyst particles? 2. Desalting Unit. b. Motor Oil Unit. ¢. Crude and Vecuum Unit. d. Fluid Catalytic Cracker.|) what type of unit suffers severe erosion-corrosion due to exposure to naphthenic acids in some crude oll? 2. Catalytic Reformer Reactor piping b. FCCU Fractionator overhead lines. c. Hydroprocessing reactor effluent piping. dd. Crude and Vacuum unit piping and vessels. 6. Pits, grooves, gullies, waves, rounded holes & valleys exhibiting 2 directional pattern are characteristics of: a. abrasion and abrasion weer. b. erosion and erosion-corrosion. . surface weathering. 4. scuffing and scraping. 6. Erosion-corrésion is best controlled by using andlor altering the process environment to reduce corrosivity. a. corrosion inhibitors b. wear plates c. hard-facing by weld overlays 4, more cotrosion-resistant alloys 7. What type of material offers improved resistance to naphthenic acid corrosion? a. Higher chrome containing alloys. b. Higher nickel containing alloys. Higher molybdenum containing alloys. |. d. Higher columbium containing alloys. 8, Inspection methods for detecting the extent of metal loss due to erosion and erosion-corrosion are: a. AE, MT and ET b. VT, UT, and RT. ¢. PT, ET, and AET d. LT, ET, and WFMT 9. What type of on stream inspection method can best detect the loss of refractory on an operating unit? 2. Visual inspection. b. infrared scan. cc. Ultrasonic scan. . Eddy current scan. 10. What i the typical erosion-corrosion rate in mpy of Monel immersed in @ seawater flume with the seawster traveling over it at 4 fps? 2.0.2 mpy b. <0.2 mpy c. 1 mpy 6.0.3 mpy"b, 4.2.14.7(¢ 10 | b, Table 4-3 mer C, 4.2.14.4{aMechanical Fatigue: Corerasig the appearance or morphology of Mechanical Fatigue, the sigaature mark of fatigue failure will typically appear as: A) Single clam shell fingerprint with vertical straight lines directly below the crack initiation site ) 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 2, Most important factor in determining component's resistance to Mech Fatigue A) Material B) Design C) Operation D) Time Page 3 of 11 Scanned by TapScan av duenliy) e stresses Ci Time!Mechanical Fatigue: 1B... API S71, Pars. 4.2.16.5.2 & Figures 4-30/31/32/33 — Mech Fatigue Question 2B... API STL, Para. 4 _a— Mechanica! Fatigue -> Critical Factors 3.D... API 571, Para. 4.2.16.6.2 — Mechanica! Fatigue > Prev & Criticat Factors4.2.16 Mechanical Fatique 4. Which of the following is caused by cycle stress often resulting from sudden unexpected failure? a. Mechanical fatigue b. Stress corrosion cracking c. Brittle fracture d. None of the above 2. The stresses for mechanical fatigue can arise from either mechanical loading or thermal cycling and are typically well : a. Above yield strength b. Above tensile strength c. Below yield strength d. Below transition temperature 3. The stress below fatigue crack will not occur is called: a. Crack limit b. Fatigue limit c. Endurance Limit. d. None of the above 4. Which of the following will have better Fatigue resistance? a. Coarse grained steel b. Fine grained steel c. Steel castings d. Alll of the above 5, Mechanical fatigue cracks are characterized by: a. Chevron marks b. Ductile failure c. Beach marks d. Endurance Marks reHi ing? 6. Which of the following is the best way to reduce fatigue cracking? a. Good design to minimize stress concentration b. Selection of suitable matenal c. Controlling operating temperature d Penodic NDT of suspected vessels 7. Fatigue cracks usually initiate on the surface at: 2 Tool markings b. Grinding marks. Mechanical notches ¢. All of the above 8. Fatigue cracks can be detected by: a PT b. MT. c. SWUT. d. Any of the abo 9. The most important factor in determining component resistance to Mechanical Fatigue is: 2. Design b Operation c. Materia 10. Critical factors related to Mechanical Fatigue and fatigue resistance include: 2. Geometry of the component 6 Stress levels & number of cycles c. Materia! propeties such as strength, hardness. and microstructure . All of these are correct4.2.16 MECHANICAL FATIGUE Qno ANS 1 A 2 c 3 c 4 8 5 c 6 A == ——— 8 D 9 Ad. Use of stethoscopes and mirrors. 4.2.16 Mechanical Failure 4. What types of material are affected by mechanical fatigue cracking? @. 300 and 400 series stainless steels are affected. b. Only carbon steel is affected. ‘G: All engineering alloys are affected. d. Monel and copper containing metals are affected.Jp. Three types of equipment with mechenice! loeding that are affected by mechanical fatigue cracking ere listed below. One of the four items listed below is not correct. Pick the incorrect item. a. Rotating shefis on centrifugal pumps thet have stress concentrations due to key ways. b, Small diameter piping that vibrates because of adjacent equipment. ¢. Large, heavy, cast steel compressor ceses @. High pressure drop control valves or steam reducing stations that have serious vibration problems. 3. A fatigue failure exhibits what type of “fingerprint” or appearance? a, The feilure exhibits a hash mark type of fingerprint that radiates from the crack origin. B, The feilute exhibits 2 “clam shel" type of fingerprint that hes concentric rings called "beach marks". ¢. The failure exhibits a wavy type of fingerprint that is random in nature. 4. The feilure exhibits @ ragged rough type of fingerprint that emanates from the failure point. 4, The best defense against mechariical fatigue cracking is which helps minimize stress ‘concentration of components that are in cyclic service. a. a material selection b, good design ¢. the use of the thinnest material aveilable 4d, good operations 6, NDE techniques such as and can be used to detect fatigue cracks at known areas of stress concentration. “a ET,AE,LT ). b. PT, MT, SWUT c. AET, WFMT, RFEC ¢. RT, PMI, FMR 6. A propeller drive shaft with varying diameters from an in-board motor to boats propeller fails due to Mechanical fatigue. Where would the failure most likely occur? a. Atthe connection to the motor. b. At the connection to the propeller. c. Anywhere in the smallest diameter. d. Ata change in diameter of the drive shaft..Mechanical Failure d, 4.2.16. 3(a) & 4216.4(b))Sulfidation: (2, Sulfidation a age is nceelerated by the preseuce of A) Hydro By Sultur Cy Salts D) Conosive Water gen 2. Which material is highly resistant to Sulfidation damage in most refining: process, environments? A) Carbon stecls B) Low alloy steels 7% Chrome C).A00 Series SS. 1 300 Series SS (304, 316, 321, 347) at metal temperatures above: Guat jon of iron-based alloys usually bey -4) 50°F (260°C) B) 700°F (370°C) C) 9005F (48: 1D) 1000°F ¢ CH YWiee Sutttation damage i found mos often (usually) appears ay: A) Localized corrosion R) High velocity erosion-corrosion ©) Unifonn thinni D) Under-deposit (scale) corrosion nerally achieved by CT Resistance to Sulfidation i ‘fy Upgrading to a higher chromium alloy B) Upsrading 1o a SS or nickel steel C} Uniization of effective hi-temp coatings 1D) None of these Page Gof 12 Scanned by TapScan. 5 renltinscecleratedcorsonoe vee a, what is used to cheek for atloy mis-ups tbat 4 Proactive and retroactive PM : 1 PMI progiams for alley vertication per AF B) Retroactive PMI programs for alloy verification per API $78. €) Proactive PMI programs for alloy veri D) Alloy verification checks (chemical sna CosresdonSulfidation: 1. A ... See Paragraph 4.4.2.1 (Description of Damage) 2.D ... Ret 4. $.4.2.3.d ... Atfected Materials & Critical Factors 3. A... See Paragraph 4.4.2.3.c (Ci i Factors) . S71, Para. 4.4.2.7.d & Reference 7... DM = .. See Paragraph 4.4.2.5.2 below (Appearance) .. See Paragraph 4.4.2.6 be!ow (Prevention) - Insp & Moaitoriag4.4.2 Sulfidation Sulfidation begins usually above: a. 300°F b. 500°F c. 150 F d. Room temperature Resistance to sulfidation is determined by a. Chromium content b. Nickel content c. Carbon content d. None of the above Proactive and retroactive PMI programs are used to check the possibility of: |. caustic corrosion sulfidation chloride scc amine sce. eaocm Susceptibility to sulfidation is determined by the___of the material. a. ability to form protective sulfide scale b. Tensile strength c. Chemical composition d. Yield strength 5. Which of the following are affected by sulfidation? a. Carbon steel b. 300 Series SS c. 400 Series SS d. Allof the above 6. Sulfidation is also known as. a. Sulfur corrosion b. Sulfate corrosion c. Sulfidic corrosion d_ None of the abovealloys are similar to stainless steels in that similarlevels of _—— 7.Nickel base ar resistance to sulfidation provide simil Chromium Nickel Carbon. d_ None of the above Sulfidation is most often in the form of uniform as: a Carbonate corrosion b. Localized corrosion. c Erosion- corrosion ¢. Band C of the above accelerated by the presence of: oom 8. thinning but also can occur 9. Sulfidation damage is a Hydrogen b. Sulfur c Salts d. Corrosive Water4.4.2 SULFIDATION ANS B A B < QNO 1 2 344.2 Sulfidation. 1. Sulfur compounds react with carbon steel in high temperature environments. This reaction causes corrosion. The presence of accelerates the corrosion. " 8. water b. carbon dioxide ©. oxygen ¢. hydrogen2. Copper base alloys form sulfide at than carbon steel. a. faster rates b. lower temperatures c. slower rates 4. higher temperatures r . , 3./Major factors affecting sulfidation are alloy composition, temperature ‘and concentration of corrosive / compounds. 2. water b. hydrogen «, sulfur d, ammonia 4, What determines the susceptibility of an alloy to sulfidation? ~ a. Its ability to form protective sulfide scales. b. The amount of nickel present. c. The ability to resist erosion gu The capability to evold graphitic decomposition. Vg A gpoitosion of iron-based alloys usually begins at metal temperatures above : \ EY 2. 800° 4 b. 700°F ) c. 600% 4 6. 500F 6. What alloying clement determines the resistance of an alloy to sulfidation? a. Nickel. b. Chrome. c. Low carbon. d, Columbium. 7. Depending on condition of service, sulfidation corrosion is most often in the form of: a. random grooving. b. uniform thinning. ¢. heavy localized pitting. d. unsystematic pitting. 8. You may achieve resistance to sulfidation by: a. using an elloy containing columbium. b, employing carbon steel alloyed with silicon. ©. upgrading to a higher chromium alloy. 4. using ¢ 70-30 copper-nickel alloy.9. To monitor equipment for sulfidation corrosion, the process conditions should be observed for increasing ‘temperatures and/or changing sulfur levels. How can you best monitor the temperature of the equipment that is subject to sulfidaticn corrosion? a. Use an experienced inspector who can visually watch for changing temperature. b. Depend upon the operators to watch for any changes in operations and inform the Inspectors. c. Use tube skin thermocouples andior infrared thermography. d. Employ temperature indiceting crayons to check for changing temperature. i 10. Crude oil with e sulfur content of 0.5 weight percent is to be heated to 650°F in a vacuum pipe crude still | cheater. Using Figure 4-65 found in API RP 571, determine the expected corrosion rate. a. About 10 mils/year. Ae b. About 4 mils/year. wv 4 u cc. About 1.0 mils/year. _d. About 0.8 mils/year.+ suifidation 1 16,44.2.1 2 |b, 4.4.2.2(c) 3 | 6, 4,4.2.3(a a, 4.4.2.3(b 5 6 | b, 4.4.2.3(d) 7 [b,4.4.2.5 | 8 | ¢,4.4.2.6(a) Po [eo 44.2.7) 10 | b, Figure 4-65High Temperature Hydrogen Attack(HTHA): 1. Regarding HTHA, which of these are critical factors for a specific material? A) Temperature, H2S concentrations, pressure, time and stress 3%) Temperature, hydrogen partial pressure, time and stress - C) Temperanure, H2S concentrations, time and stress D) None of these are correct 2. What chrome moly combinations are not susceptible to HTB at conditions normally seen in refinery units? A) At least 1.25% Cr and 4% Moly B) At least 2.25% Cr end 1% Moly C) At least 5% Cr and 1% Moly + Dj At least 7% Cr and 1% Moly are not susceptible > 3. Which of these mechanisms is difficult to distinguish from HTH in the early stages! A) Wet H2S Damage (Blistering & HIC) B) Hi-Temp H2/H2S Corrosion C) Sulfidation D) Creep7 4. Due to HTHA considerations. what steel alloy is no longer recommended for new construction in hot bydrogen services? A) UT velocity ratio & backscatter B) MT or PT C) WEMT D) RT 6. Which of these safety factors is employed in normal design practice when using the APT RP 941 Curves regarding HTHA? AD 12°F to 25°F (75°C to 12 pb) 2SSF to 5 C) 50°F to 00°F SC to $8°C4 D) None of theseHTHA): Att igh Temperature Hy LB... Ref: 5.13.13. ... RTHA Corr > Critical Factors. .- Ref. $.1.3.1.2 & 5.13.1.3.f... Affected Materials & Critical Factors -HTHA in early stages is difficalt to distinguiss from CREEP 3.D... 571 Par. 5. 4. B .. See Paragragh 3.13 1.4.c&d below > HTHA > Prevention Mitigation ection & Moritoring S.A... See Pangnph 5:13.1.7b9 ine: . Prevention Mitigation > RP 941 Safety Factor & Likely Open Book .. DMAttack (HTHA 5.1.3.1 Hiah T re H 4. HTHAis caused by formation of: a Graphics b Methane c Sulfide dé Hydnde 2. Which of the following material !s highly resistant to HTHA? a CrO5Mo b §0Cr-0.5Mo ¢ Cr10Mo co All of the above 3, _HTHA can be confirmed through the base of: PT Metaliographic analysis Ultrasonic scanning's Profile Rasiography aoa elocity ratio and, have 4. Ultrasonic techniques using a combination of v .d or serious cracking? been the most successful in finding fissuring an aaow 5.300 Series SS. SCr. 9Cr and 12Cr alloys are not susceptible to at conditions normally seen in refineries. 2 CSCC SOIC HTHA a HTLA ty oo 6. Due to HTHA consicerations, whet steel alloy is no longer recommended for new construction in hot hydrogen services? a Mn% Me b1%Cr hie c tCry to eo C-051465.4.3. 1 HTHA ANS4 Hi ure Hydrogen Attack (HTHA| 4. High temperature hydrogen attack (HTHA) results from exposure to hydrogen st elevated temperatures and pressures. The hycrogen reacts with carbides in steel to form methene (CH,) which cannot diffuse through the steel. The loss of, causes an overall loss of strength. a. carbide b, carbonate ©. calcium d. iron 2. Which of the materials listed below is the least resistant to HTHA? a. 300 series stzinless steel. b. 400 series stzinless steel c. 9Cr-1Mo. . Carbon steel. igure §-36 of API RP 571, for a hydrogen partial pressure of 2500 psi, and a 3. Using the curves in zterial should be picked for use? temperature of 600 degrees F., what 2. 2.26Cr-0.5Mo. 'b. 3Cr-1Mo. c. 1.25Cr-0.5Mo. d. Carbon steel.Vf i J 4/Some units affected by HTHA ere listed below. One of the ones listed is usually not considered ¢ target. \¥ Pick this unit. a, Hydrocracker. / b, Crude still. \ . Catalytic Reformer. d. Hydrotreater. 5. Early stages of HTHA can only be confirmed through advanced: a, acoustic emission testing b. wet fluorescent magnetic particle testing, ©. ultrasonic techniques such as SWUT. d. metallographic analysis of damaged areas 6. Cracking and fissuring caused by HTHA are and occur adjacent to peariite (iron carbide) creas in carbon steels. a. surface oriented b. subsurface ¢. laminations d. intergranular 7. When using the API RP 941 curves for selecting an alloy steel for use, what increase in temperature is used as'a safety factor? —eror— } a. 10 to 20 degrees F. b. 75 to 100 degrees F. / 6. 100 to 200 degrees F. . 25 to 60 degrees F. '8:What meterial hes been removed from the Nelson curves shown in Figure 5-35 of API RP. 574 and in API RP 9417 i j a. 8Cr-0.5Mo 7 / 8, Damage from HTHA occurs in welds or weld heat affected zones as well as in the base metal. j / a. carly b. randomly c. late d. occasionally AAO. Whats not 2 proven method for the detection of HTHA damege? 4un b.AET. ©. WEMT. o. RTHow do you inspect for HTHA? a. Eddy current, leak testing, and hemmer testing. b. Acoustic emission testing is the best way to test for HTHA. ©. Specialized UT, VT for blisters, WFMT and RT. d. There are no good ways to inspect for HTHA damage. 42. How do you prevent HTHA? a. Use the Nelson curves 2s a besis for selection of meterials for use where HTHA is a problem. lb. Careful ‘management of operations will prevent the formstion of methane when carbon contacts hydrogen. \ ¢. Since HTHA\is difficult to prevent, renewing material on 2 scheduled basis will prevent failures. d. Special coatings recommended by NACE will reduce and prevent HTHA if applied correctly. 13. At what temperature would you éxpect high temperature hydrogen attack te occur? a. HTHA begins at about 500°F. ‘I |b. HTHAis dependent upon material, temperature, hydrogen partial pressure, time, and stress. ! c. HTHA\is only present at hydrogen partial pressure above 500 psi and temperatures over 500°F. nd None of the above. 54.2.9 Titanium Hurleidineb, 5.7.3.1.3 & Fig 5-35nuaaeoren Corrosion Under (CLL: (1, CUI becomes more severe at this metal temperature rauge (where water is less likely to Saporize and insulation stays wet longer) between (Note: Give the 2003 Edition value): A) TI2DF EOC ent te y i SF (100°C) 0 above (unlimnec SF (100% 1 1) Cyto SOR ITO) 2. 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 shen ention of CUI is best achieved by: —S A) Carefully planned percdic inspections B) Careful visual exam of msulanen covers 2) Employment of qualiny coatings D)} Nene of these are correct * Page sofli‘D} Hammer test aed thermogtaph ple dl neutron & end pernal sirippingCorrosion Under Corrosion fCU}: . Refi 4. Par. 4.5,3.3:d ... i change in 2011 2™* Edition = 350F (1750) > CF 3.¢ ... Critical Factors . See Paragraph 4.2.3.7.2 {Preveniion) ». See Paragraph 4.3 7.€.2 Sulleis (Insp & Monitoring)4.3.3 Corrosio: ‘osion Under Insulation (CU!) Which of the following material will CUI affect? a. Carbon steel b. Low alloy steel c. Austenitic stainless steel d. All of the above CUI will appear in Austenitic stainless steel as: a. General corrosion b. Chloride stress corrosion cracking c. Caustic stress corrosion cracking d. Hydrogen induced cracking For insulated carbon steel components corrosion become more severe at metal temperature between: a. 10 °F to 350°F b. 212°F to 350°F c. 140°F to 350°F d. None of the above Which of the following equipment are not susceptible to cul: a. Piping or equipment with damaged /leaking steam tracing b. Localized damage at paint or coating systems c. Termination of insulation in a vertical pipe d. Equipment located at upstream of cooling towers The CUI mitigation is best achieved by: a. Controlling the operating temperatures b. Performing 100% visual inspection c. Maintaining the insulation and sealing vapor barriers d. Using low chloride insulation Which of the following will reduce the possibility of CUI? a. Using closed cell foam glass insulation b. Controlling operating temperatures c. Operating temperature at 10°F to 350°F d, All of the above7. Which of the following NDT methods will detect wet insulation? a PT b UT ¢ Neutron backscatter ¢ Deep penetrating eddy current inspection 8. With CUI, corrosion rates with increasing metal temperatures up to the point where the water evaporates quickly. 2 Decrease b. Increase c. Stey the same a None of the above 9. Prevention of CUI is best achieved by: Carefully planned periodic inspections Using quality coatings Careful visual exam of insulation covers 6. None of these are correct. 10. Insulating materials often “hold moisture” that creates corrosion. The ability of insulation to draw and hold water or moisture is known as: 2 Wicking b. Saturation c. Wetting ¢. None of these are correct ooo 441. Location of equipment is a concer for CUI. Areas of high moisture that require close surveiliance of CU! 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 12. Poor design and/or installations that allow water to become trapped will increase: a Cul b. Atmosphenc corrosion c. Galvanic corrosion d. Allof the above4.3.3 CORROSION UNDER INSULATION(CU!) Qno ANS _ no | \ | | | | ulelwin| | | | |||) a h = N |4. VT and UT 4. Corrosion Under insulation {CU} 4, What is the cause of corrosion under insulation (CUI) of refinery end chemical plant equipment? a. The corrosion is caused by not having an on-going and complete inspection program. b. The corrosion is caused by long term lack of maintenance. The corrosion is caused from the use of the wrong material for the equipment. ine corrosion results from weer trapped under insulation and fireproofing.Y , What materials are usually affected by CUI? a. Cast iron, Nickel 200, and Aluminum. b. Titanium, Duranickel slloy 301, and Copper nickel . Monel, Incoloy, and Inconel. 4. Carbon steel, low alloy steels, 300 series and duplex stainless steels. 3. What temperatures cause CUI to be most severe? a. Between 100°F and 150°F b. Between 212°F and 250°F ¢. Between 100°F and 212°F d. Between 260°F and 300°F 4, An inspector notes that there are cracks in the brick fireproofing of a column supporting a vessel on @ FCC nit An ingpection hole is opened to check the condition of the column. Heavy rust scale is present and the inspector requires the entire column to be stripped. Severe piting to holes and serious thinning of the column is found, What type of corrosion would this be? a Heavy erosion from catalyst. b. Chloride attack. c. Normal weathering of the column. 4. CUI (corrosion under insulation), 5; If insulation has chlorides in itto cause CUI related to stress corrosion cracking, what type material or equipment would be the most susceptible to damege? \ a. 400 series of stainless sieels. / bp. 300 series of stainless steels. ¢. Carbon and low alloy steels. d. Duplex stainless steels. 6. Three of the four items listed below are locations where CUI may be @-problem. Which one of the four items would not be of concern? ‘a. Insulated piping operating at 350°F. b. Areas with damaged insulation. ¢. Insulated equipment down-wind from cooling towers, d. Equipment with leaking steam tracing. 7. A'small pressure vessel made of 316 stainless steel is to be insuleted. it operates at 220°F in an area subject lo 2 lot of weter vapor. The inspector checks the insulation that is to be used and finds that it contains chlorides. What should he do? 2. Stop the installation ofthe insulation and make arrangements to have lowino chloride insulation installed. b. Make sure the area is covered during the installation of the insulation to avoid moisture being trappec. c. Nothing is required-the insulation is satisfactory. d. Heat the vessel to 300°F during the installation of the insuletion. 8. If wet ineulation is suspected on @ vessel or if damaged and missing insulation is suspected beneath en lurninum jacket on 2 vessel, what inspection method would be best to find the locations? . Strip the insulation completely and renew it. . Infrared thermogrephy. . Rediograph the equipment |. Magnetic flux leakage. aopgea, 4.3.3.3(0) & 4.3.3.6(a)(bWet HoS Damage (Blistering/HIC/SOHIC/SSC): 1. Regarding wet B2S damage, hydrogen blisters result from: (select most correct Ans): d corrosion A) Hydrogen that is generated by hydrogen gas coming from the proc B) Hydrogen that is generated by hydrogen gas coming from the process stream only C) Hydrogen that is generated by corrosion D) None of these is correct2. Wet HoS damage affects: AY Carbon steels oh w alloy sicels and 400 series SS els Tew allos steels, 400 series SS and some N' 2. What NDI method requires least amount of preparation to find Wet H'S cracking” A) SWUT B) WEMT CvPT 0) ACEM 4. PWHT is highly effective in preventing this wet H°S damage mechanism: Aj Bustering B) SOHIC c) ssc D) HICWet H2S Damage (Blistering/HIC/SOHIC/SSC): 1.0... Ref: $.123.1.2& Fi Descrintion of Damzge (Wei H2S > Blistering} 3... Affected Maresials (Wet eke D ... Sez Para. §.1.2.3.7.2 (Inspection and Mex ng) SE .. Critical Feczors ABisce tot 4.C... See Pare. 5.15.1.2.3 Wet H2S Damage (Blistering/HICISOHICISSC) bulges on the ID ,the OD or Which of the following may form as surface vessels due to hydrogen 2 within the wall thickness of pipe or pressure a HIC b SOHIC c. Hydrogen blisters d SSC SSC generally occurs below about: a. 300°F b 180‘°F c 350°F a 212°F TO avoid SSC low strength carbon steels used in refinery applications should be controlled to produce welds hardness below? a 250HB b 241 HB c. 200HB ¢. 225HB Which of the following will be prevented effectively by PWHT? a. Hydrogen blisters b HIC c SSC ¢. Allof the above SOHIC and SSC damage is most often associated with: 2. HAZ b. Base metal c. Weldment d Branches Which of the following preparation methods is used for WFMT? GRIT blasting High pressure water blasting Both of the above None of the above aogp7. __and. damage develop without applied or residual stress so that PWHT will not prevent them from occurring. a. SOHIC, Blistering b. SCC, SOHIC c. HIC, SCC. d. Blistering, HIC 8.Sulfide stress cracking (SSC) is defined as cracking of metal under the compinse! action of tensile stress and corrosion in the presence a an a. Sulfur, Oxide b. Hydrogen, water c. H?S, Oxygen d. Water, HS. 9. SSC is a form of. stress corrosion cracking. a. Hydrogen b. Caustic c. Polythionic d. Alkaline 10. is similar to HIC but is a potentially more damaging form of cracking which appears as arrays of cracks stacked on top of each other. The result is a through thickness crack that is perpendicular to the surface and is driven by high levels of stress. a. MIC b. SOHIC c. Sulfuric SCC d. None of the above AA; is most likely found in hard weld and heat-affected zones and in high strength components. a. HIC b. SSC c. SOHIC d. Blistering 42. Inspection for wet H2S damage generally focuses on weld seams and__ a. HAZ b. Nozzles c. Trays d. Down comervia|ulylyu|yusa|a|<)a)a\,eu ANS 5.1.2.3 Wet H2s Damage Oo Z\a|njm[wlajojn|@e/aiai ala4d. API RP 945 - 6.1.2.9 Wet H2S Damage (Blisterinq/HIC/SOHIC/SCC). /4. Hydrogen atoms that colisct in & discontinuity in steel (inclusion or lamination) combine and form hydrogen gas, which eccumuletes end ceuses @ blister. The hydrogen atoms originate from: 2. hydrogen ges from the process stream. - b. corrosion in the system c. welding with H;O present; thus, liberating hydrogen. d. high temperature annealing of the equipment: thus, releasing hydrogen) 2. Hydrogen blisters can form at many different depths in steel. In somé cases, neighboring or adjacent isters that are at slightly different depths (planes) may develop cracks that link them together. interconnecting cracks between the blisters offen have é stair step appearance. This type of wet H2S damage is often referred to as: a. planar hydrogen induced cracking. b. HIC or hydrogen induced cracking. ¢. HCC or helium caused cracking. |. interlocking blister cracking. 7a)siress oriented hydrogen induced cracking (SOHIC) is a more damaging form of cracking than HIC. —SOHIC resulis in a through-thickness crack that is perpendicular to the surface and is driven by high levels of stress (residual or applied). The cracks usually: . appear in the weld metal in the center of the weld where they initiate from HIC or other cracks or defects including sulfide stress cracks. », appear in the base metal away from weld heat affected zones where they initiate from HIC or other cracks or defects including sulfide stress cracks. c. appear in the base metal edjecent to the weld heat affected zones where they initiate from HIC or other cracks or defects incluairig Sum a d. appear in the weld metal adjacent to the weld heat affected zones where they initiate from HIC or other cracks or defects including sulfide stress cracks. '4, Sulfide stress corrosion cracking (SCC) can initiate of steels in highly localized zones of high hardness in the weld metal and heat affected zones. a, subsurface ) b.in the center "con the surface d. near the center 5, What is beneficial in reducing the hardness end residual stresses that render a steel susceptible to SSC? a. Post weld heat treatment. b, Use at least a 9Cr-1Mo material. c, Use of high nickel consumables. d. Use of tempered materials. 6, What material is affected by Blistering/HIC/SOHIC/SSC? a, All metals and alloys. 7&300 series stainless steel end duplex stainless steels, c. Carbon and low alloy steels, d. 400 series steinless steel and high nickel alloys. 7. The most important variables that effect end differentiate the various forms of wet HaS damage are listed below. One is incorrect. Pick the incorrect one. a. Environment conditions (pH, HS level, contaminants, temperature). b. Engineering capabilities (readily febriceted, resistance to oxidation and carburization). ©. Material properties (hardness, microstructure, strength). 4. Tensile stress level (applied or residual).— _)8, Allwet H,S damage mechanisms ere related to the absorption and permection of. in steels. a. sulfur b. nitrogen ©. oxygen ~~ a hydrogen & 9, Hydrogen permeation or diffusion rates have been found to be minimal at: a.pk9. b.pH7. c. pH 5. 4. pH 3. 10. Hydrogen permeation or diffusion rates increase at: 2, pH lower then 7. Ae b. pH higher then 7. c. pH higher and lower than 7. fo~8. pH equal to 7. Ay ee ai 44, Some of the conditio’s that are known to promote blistering, HIC, SOHIC and SSC, are those containing free water (in quid phase). Some of these ere listed below. Pick the one that does not belong. a, Free water with pH less than 4-and some dissolved H.S present. b. Free carbon dioxide with pH less than 7 and some H2S present. . co Free water with pH greater-than 7.6 and 20 wppm dissolved HCN in the water with some H,S present, ) d. Greater than 50 wpm dissolved HS in the free weter. 42, An arbitrary value of H,S in the weter phese is often used as the defining concentration where wet HaS damage becomes @ problem. 2. 30 wpm b. 50 wppm -<. 70 wppm ¢ 4.90 wppm ! degrees F. or | 13, Blistering, HIC, end SOHIC damage have been found to occur between ambient and i higher. — / ¥ a. 100 b. 200 ©. 300 4.500 fo % 14.8SC generally occurs below about degrees F. a, 340 .% b.225 ‘ ©. 180 ny 4. 150 *45. Hardness is primarily an issue with SSC. Typical low-strength carbon steels used in refinery application ‘should be controlled to produce weld hardness less than HB. a. 240 b. 200 ©. 140 d. 100 46, Blistering, HIC and SOHIC damage are not related to: a, H,S content of the product, b. steel hardness. c. pH of the product. d. temperature of the product. 17. Blistering and HIC damage are strongly affected by the presence of inclusions and laminations which provide sités for diffusing to accumulate, a. hydrogen b. cyanide c. oxygen 4. nitrogen A, the following wet H2S damage develops without applied or residual stress so that PWHT will not prevent them from occurring. 4 a: SOHIC and SSC. b. Blistering and'HIC. ¢. CISCC end CSCC. ¢. HTHA and CUI. 19. PWHT is highly effective in preventing or eliminating by reduction of both hardness and residual stress. a. HIC b. blistering SSC 4, HTHA 20. is driven by localized stresses so thet PWHT is somewhat effective in reducing its damage. Ree eee a. HIC b. SOHIC . Biistering d. CSCC 21. significantly increase the probability and severity of blistering, HIC and SOHIC damage. 2. Nitrogen b. Oxygen c. Cyanides d. Chlorides) ‘22. ‘eppear 2s buiges on the ID of OD surfece of the steel and can be found anywhere in the shell plate or head of ¢ pressure vessel. @.HIC cracks b. SSC effects ryuer c. SOHIC attacks 5 d. Hydrogen blisters - 23. Alloy cladding and coatings, process changes, HIC resistant steels, limiting steel hardness, PWHT, and corrosion inhibitors are all meens of wet H,S damage. 2. promoting or increasing bb. preventing or mitigating . eliminating or changing 4d. disseminating or moderating 24) Inspection for wet H»S damage generally focuses on: ‘a, piping and pumps. b. shall plates and tank bottoms c. vessel heads and M/W covers. d, weld seams and nozzles. 25. What is an acceptable method for determining the crack growth caused by wet HS attack? a. AET ) b.UT Jc. WEMT a.PT wn thee na Adtnnle HUTLAYWet H,S Damage ae 5123.16) “34 _{ d, 5.1.2.370 25 | a,5.1.2.3.7 |