API 571

1. A 5Cr-1Mo piping system in the hydrogen unit shows 7. 300 Series SS is susceptible to LME when it comes in contact
significant internal wall loss after 2 years in service due to with Molten _________.
CO² corrosion. Which material would be best suited to use
to install a new pipe system? A. Cadmium
B. Mercury
A. Titanium C. Zinc
B. 9Cr-1Mo D. Lead: C
C. A-106 Gr B 8. 300 Series stainless steel heater tubes in an oil-burning
D. 316 SS: D furnace in the hydrocracker began to leak and the furnace
2. A 6", A106 Gr B, flanged line carrying caustic wash water at was brought down. What was the probable cause of the
200°F has signs of atmospheric corrosion. Which of the cracking?
following may help accelerate the corrosion?
A. Chloride stress corrosion
A. Sulfides B. Polythionic acid stress corrosion
B. Fly ash C. Amine stress corrosion
C. Caustic D. Stress oriented hydrogen induced cracking.: B
D. None of the above: B 9. The accepted way to test for temper embrittlement is
3. 300 Series SS, 5Cr, 9Cr, and 12Cr alloys are not susceptible __________.
to __________ at conditions normally seen on refineries.
A. Impact testing
A. Cl SCC B. Metallographic
B. SOHIC C. RT
C. HTHA D. UT shear wave: A
D. HTLA: C 10. _________ acid is most often used as a catalyst in
4. 300 Series SS, 400 Series SS and duplex SS are subject to polymerization units.
pitting and localized corrosion under insulation. In addition,
__________ are also subject to SCC if chlorides are present, A. Polythionic
while _________ are less susceptible. B. Naphthenic
C. Phosphoric
A. Duplex SS, Low alloys D. Sulfuric: C
B. 300 Series SS, Duplex SS 11. All _______ based materials and low alloy materials, 300 Series
C. Duplex SS, 300 Series SS SS and 400 Series SS are susceptible Sulfidation.
D. None of the above: B
5. 300 Series SS can be used for sour water service at A. Carbon
temperatures below _________, where Chloride SCC is not B. Steel
likely. C. Chromium
D. Iron: D
A. 120°F 12. Alloy 400 susceptible to LME when it comes on contact with
B. 140°F molten __________.
C. 150°F
D. 175°F: B A. Cadmium
6. 300 Series SS can suffer pitting corrosion, crevice corrosion B. Mercury
and ________ in fresh, blackish and salt water. C. Zinc
D. Lead: B
A. General corrosion 13. Alloys with increased amounts of ______ show improve
B. Oxidation resistance to naphthenic acid corrosion.
C. SCC
D. None of the above: C A. Chromium
B. Molybdenum
C. Nickel
D. Carbon: B
14. Alloys with Nickle content above ________ are highly resistant 20. Amine corrosion refers to the general and/or localized that
to CI and SCC. The greatest susceptibility is 8% to 12% occurs principally on ______ in amine treating process.
nickel. Corrosion is not caused by the amine itself, but results from
dissolved acid gases (CO² and H²S), amine degradation
A. 15% products, heat stable amine salts and other contaminants.
B. 20%
C. 30% A. Carbon steel
D. 35%: D B. Duplex SS
15. All piping and equipment exposed to HF acid at any C. 300 Series SS
concentration with hardness levels above ________ are D. 400 Series SS: A
subject to hydrogen stress cracking. 21. Amine cracking has been reported down to ambient
temperatures with some amines. ______________ temperatures
A. 200 BHN and stress levels__________ the likelihood and severity of
B. 210 BHN cracking.
C. 227 BHN
D. 237 BHN: D A. Increasing, increases
16. All piping and equipment exposed to HF acid at any B. Increasing, decreases
concentration with hardness levels above the C. Decreasing, increases
recommended limit (237 BHN) are subject to __________. D. Increasing, reduces: A
22. Amine cracking is a form of ________ stress corrosion cracking.
A. Hydrogen stress cracking
B. Sulfide stress cracking A. Hydrogen
C. Chloride stress cracking B. Caustic
D. None of the above: A C. Polythionic
17. Although cracks may be seen visually, crack detection for D. Alkaline: D
caustic stress corrosion cracking is best detected by WFMT, 23. Amine cracking is ________ likely to occur in lean MEA and
EC, RT and ________. DEA services than in MDEA and DIPA services.

A. PT A. More
B. MT B. Less
C. ACFM C. As
D. All of the above: C D. None of the above: A
18. Although the loss of toughness from temper embrittlement 24. Amine stress corrosion cracking is a term applied to the
is not evident at operating temperatures, equipment that is cracking of steels under the combined actions of _________
temper embrittled may be susceptible to __________ during and __________ in aqueous alkanolamine systems used to
start-up and shutdown. remove/absorb H²S and/or CO² and their mixtures from
various gas and liquid hydrocarbon streams.
A. Thermal fatigue
B. Cyclic Stress A. Temperature, pressure
C. Notch toughness B. Pressure, stress
D. Brittle fracture: D C. Temperature, corrosion
19. Amine corrosion depends on the design, operating D. Tensile stress, corrosion: D
practices, the type of amine, amine concentration, 25. Amine stress corrosion cracking is most often associated
temperature and ________. with lean amine services. The pure alkanolamine does not
cause cracking. Cracking in rich amine services are most
A. Pressure often associated with _________ problems.
B. Velocity
C. Stress A. H²S
D. None of the above: B B. Stress
C. Wet H²S
D. Temperature: C
26. Amine units are used in refineries to remove H²S, CO² and 32. Annealed steels are more resistant to Spheroidization than
________ from process streams originating in many units normalized steel. _________ grained steels are more resistant
including the coker, crude, FCC and hydrogen. that ________ grained steels.

A. NA² A. Fine, Course

B. CI² B. Course, Fine
C. Mercaptans C. PWHT, Non-PWHT
D. None of the above: C D. Non-PWHT, PWHT: B
27. Ammonium chloride corrosion is the general or localized 33. Application of post-fabrication stress relieving heat
corrosion, often pitting, normally occurring under treatment of about ___________ is a proven method of
ammonium chloride or amine salt deposits. All commonly preventing carbonate cracking.
used materials are susceptible to ammonium chloride
corrosion. A small amount of _________ can lead to very A. 1100°F
aggressive corrosion. B. 1150°F
C. 1200°F
A. Ammonium chloride D. 1250°F: B
B. Amine 34. Areas of vulnerability in sulfuric acid Alkylation units
C. Water include reactor effluent lines, reboilers, deisobutanizer,
D. Salt: C overhead systems and the _______ treating system.
28. Ammonium chloride salts are hydroscopic and readily
absorb water. A _________ amount of water can lead to very A. Caustic
aggressive ammonium chloride corrosion. B. Sulfuric acid
C. Catalyst
A. Large D. H²S: A
B. Small 35. ___________ are characterized by a localized loss on thickness
C. Proper in the form of pits, grooves, gullies, waves, rounded holes
D. Improper: B valleys. These losses often exhibit directional pattern.
29. Ammonium chloride salts may be whitish, greenish or _______.
A. Erosion
A. Reddish B. Corrosion/Erosion
B. Brownish C. Environmental corrosion
C. Yellowish D. Both A and B: D
D. Bluish: B 36. _________ are the most common type of equipment
30. The amplitude and frequency of vibration as well as the ___ susceptible to carburization in the refining industry.
of the components are critical factors in vibration-induced
fatigue. A. Reactors
B. Heat exchanges
A. Velocity C. Heater tubes
B. Temperature D. Fin Fans: C
C. Fatigue resistance 37. ASME Section VIII had few limitations concerning brittle
D. Material properties: C fracture prior to:
31. _________ and _________ damage develop without applied or
residual stress so that PWHT will not prevent them from A. 1955
occurring. B. 1962
C. 1973
A. SOHIC, Blistering D. 1987: D
B. SCC, SOHIC 38. At a given pressure, the H²S concentration in the sour water
C. HIC, SCC _______ as temperature _________.
D. Blistering, HIC: D
A. Increases, increases
B. Decreases, decreases
C. Increases, decreases
D. Decreases, increases: D
39. At elevated temperatures, dissimilar weld metal cracking is 46. The Best way to prevent 885°F embrittlement is to use low
aggravated by the diffusion of carbon out of weld metal ____ alloys, or to avoid exposing the susceptible material to
and into the base metal. The temperature at which carbon the embrittlement range.
diffusion becomes a concern is above ___________.
A. Austenite
A. 700°F B. Martensite
B. 750°F C. Ferrite
C. 800°F D. Chromium: C
D. 900°F: C 47. The best way to prevent failures by atmospheric corrosion is
40. At elevated temperatures, the carbide phases in certain to:
carbon steels are unstable and may decompose into
___________. This decomposition is known as graphitization. A. Have an aggressive inspection program
B. Reduce airborne particles
A. Silicon C. Install and maintain appropriate coatings
B. Graphite nodules D. Shoot all birds that cross the plant fence
C. Carbon dust E. Build new petrochemical facilities in a dry desert.: C
D. Graphite dust: B 48. Blistering, HIC and SOHIC have been found to occur
41. At high temperatures, metal components can slowly and between ambient and ________.
continuously deform under load below the yield stress. This
time dependent deformation of stress components is A. 250°F
known as _________ B. 300°F
C. 350°F
A. Deformation D. 400°F: B
B. Fatigue 49. Blistering, HIC, SOHIC, SSC damage can occur wherever
C. Creep there is a __________ environment.
D. Thermal Fatigue: C
42. At high temperatures, metal components can slowly A. Wet H²S
continuously deform under load below the yield strength. B. Hydrogen
This time dependent deformation of stressed components C. Sulfur
is known as ___________. D. Aqueous: A
50. A brittle fracture:
A. Creep
B. Ductility A. is caused by stress cycles
C. Softening B. Is always the result of thermal stresses
D. Hardening: A C. Grow very rapidly with minimum deformation prior to
43. Atmospheric corrosion: failure
D. Grows slowly and is dependent on time and stress.: C
A. Can cause either uniform or localized wall loss 51. Brittle fracture can occur during ambient temperature during
B. Always causes localized wall loss a hydro-test due to:
C. Always causes uniform wall loss
D. Is best detected using profile RT: A a. unusual loading and high toughness at the testing
44. Atmospheric corrosion is of greatest concern in: temperature.
b. high impact stresses and plasticity at the testing
A. Dry climates in rural locations temperature.
B. Dry climates in industrial locations c. high stresses and low toughness at the testing
C. Wet climates in rural locations temperature.
D. Wet climates in industrial locations.: D d. high strength material and temperatures below 100
45. The best method to inspect for SCC is _________. degrees F.: C
52. Cadmium and lead will cause LME on ___________.
A. WFMT
B. UT Shear Wave A. Copper alloys
C. AET B. 300 Series SS
D. All of the above: A C. Aluminum alloys
D. High strength steel: D
53. Carbonate cracking typically propagates ________ to the weld; 60. Carbon steel and low alloy steels are subject to excessive
the pattern of cracking observed on the surface is hydrochloric acid corrosion when exposed to any
sometimes described as _______. concentration of HCI acid that produces pH below _____.

A. Transverse, Eyebrow A. 6.0

B. Parallel, Spider web B. 5.5
C. Diagonal, Half moon C. 5.0
D. Perpendicular, Stair step: B D. 4.5: D
54. Carbonate SCC can occur at relatively low levels of _________ 61. A carbon steel bundle from the overhead condenser in the
but usually occurs at welds that have not been stressed crude unit operates at 300°F and is in hydrochloric acid
relieved. service. It showed severe pitting type corrosion when
pulled for inspection. What type of material would be best
A. Residual stress suited for this service?
B. Applied stress
C. Acid concentration A. 5Cr-0.5Mo
D. Non of the above: A B. 316 SS
55. Carbonate SCC may easily be mistaken for SCC or SOHIC; C. 9Cr-1Mo
however, the carbonate cracks are usually ________ the toe of D. Titanium: D
the weld and have multiple parallel cracks. 62. Carbon steel is susceptible to SCC when used in _________
service.
A. Further from
B. Closer to A. Hydrogen
C. Diagonal to B. Ammonia
D. Perpendicular to: A C. High temperature
56. Carbonate stress corrosion cracking is the term applied to D. High pressure: B
surface breaking or cracks that occur adjacent to carbon 63. Carburization can be confirmed by a substantial increase
steel welds under the combined action of __________ and hardness and a ________ in ductility.
_______ in carbonate containing systems.
A. Loss
A. Temperature, stress B. Gain
B. Tensile stress, corrosion C. Change
C. Corrosion, velocity D. None of the above: A
D. Tensile stress, velocity: B 64. Carburization can be confirmed by substantial increases in
57. Carbonate stress corrosion cracking usually occurs at welds _______ and loss of _________.
or cold worked areas that ___________.
A. Hardness
A. Have been stresses relieved B. Tensile strength
B. Have not been stresses relieved C. Ductility
C. Have high residual stress D. A and B
D. Have high applied stress: C E. A and C: E
58. Carbon dioxide (CO²) corrosion results when CO² dissolves 65. ___________ caustic concentrations and ________ temperature
in water to form _________. increase the likelihood and severity f cracking with caustic
embrittlement.
A. Carbon monoxide
B. Carbonic acid A. Increasing, Decreasing
C. Hydrofluoric acid B. Decreasing, Increasing
D. None of the above: B C. Decreasing, Decreasing
59. Carbon dioxide corrosion results when CO² dissolves in D. Increasing, Increasing: D
water to form _______ acid. 66. Caustic embrittlement cracking can be effectively
prevented by means of PWHT at a temperature of _______.
A. Sulfuric
B. Hydrochloric A. 1100°F
C. Carbonic B. 1150°F
D. None of the above: C C. 1200°F
D. 1250°F: B
67. Caustic embrittlement is a form of ___________characterized by 73. Changing to a more corrosion resistant and/or higher
surface-initiated cracks that occur in piping and equipment hardness material _______ improve cavitation resistance.
exposed to caustic, primarily adjacent non-PWHT'd welds.
a. galvanic cracking A. Will
b. stress corrosion cracking B. May
c. Chloride cracking C. Will Not
d. fatigue cracking: B D. May Not: D
68. Caustic embrittlement is a form of stress corrosion cracking 74. Characteristics stress corrosion cracks have many branches
characterized by surface-initiated cracks that occur in and may be visually detectable by a _____________ appearance
piping and equipment exposed to caustic, primarily adjacent on the surface.
to non-PWHT welds. Which of the following materials is the
most resistant to embrittlement? A. Tree shaped
B. Craze-cracked
A. Carbon steel C. Multiple crack
B. Nickle based alloys D. None of the above: B
C. Low alloy steels 75. The CI SCC surface cracks appear under the action of
D. 400 Series SS: B ________, temperature and an aqueous chloride environment.
69. Caustic is sometimes added to process streams for _________ a. stagnant conditions
or as a reactant. b. high velocity products
c. compressive stress.
A. Stability d. tensile stress: D
B. Corrosion control 76. Cl SCC usually occurs at metal temperatures above _________.
C. Neutralization
D. Inhibiting: C A. 125°F
70. Caustic stress corrosion cracking typically propagates B. 175°F
________ to the weld in adjacent base metal but can occur in C. 140°F
the weld deposit or heat affected zone. D. 200°F: C
77. Components that have been carburized may have a change
A. Transverse in the level of _____________.
B. Perpendicular
C. Parallel A. Carbon
D. Across: C B. Chromium
71. Cavitation is a form of erosion by the formation and C. Ferromagnetism
instantaneous collapse of innumerable tiny vapor bubbles. D. Stress: C
Temperature approaching the boiling point of the liquid are 78. Conditions favoring carburization include a high gas phase
_________ to result on bubble formation. carbon activity and ________ oxygen potential.

A. Less likely A. Low

B. More likely B. High
C. Not likely C. Negative
D. None of the above: B D. Positive: A
72. Cavitation is best prevented by avoiding conditions that 79. A condition where steel loses strength due to the removal
allow the absolute pressure to fall below the _____ of the of carbon and carbides leaving only an iron matrix is called
liquid or by changing the material properties. decarburization. This occurs during high temperatures,
during PWHT and from exposure to fires. Which of the
A. Minimum pressure following materials is not affected by this?
B. Pressure/Vapor ratio
C. Maximum pressure A. Low alloy steel
D. Vapor pressure: D B. Duplex SS
C. Carbon Steel
D. None of the above: B
80. Contrary to a pure mechanical fatigue, there is no ________ 87. Corrosion by HF (Hyrdofluoric) acid can result in high rates
load in corrosion-assistant fatigue. Corrosion promotes of general or localized corrosion and may be accompanied
failure at a lower stress and number of cycles that the by hydrogen cracking, blistering and ________.
materials normal endurance.
A. HIC
A. Tensile B. Delayed cracking
B. Stress C. SOHIC
C. Ductile D. Both A and C: D
D. Fatigue limit: D 88. Corrosion due to acidic sour water containing H²S at a pH
81. Convert these temperature ---- 156°C, 450°F. between 4.5 and 7.0 is called sour water corrosion. Carbon
dioxide (CO²) may also be present. Which of the following
A. 304°F, 151°C materials is susceptible to sour water corrosion?
B. 284°F, 218°C
C. 312°F, 232°C A. Carbon Steel
D. 296°F, 246°C: C B. 300 Series SS
82. Cooling water corrosion and _________ are closely related and C. 400 Series SS
should be considered together. D. Both B and C: A
89. Corrosion from oxygen in boiler feed water usually creates:
A. Stress
B. Velocity A. Uniform corrosion
C. Fouling B. Isolated pitting
D. Erosion: C C. Intergranular cracking
83. Cooling water corrosion can result in many different forms D. Transgranular cracking
of damage including general corrosion, pitting corrosion, E. Hard and brittle zones: B
_________, stress corrosion cracking and fouling. 90. Corrosion from oxygen tends to be _________ type damage
and can show up anywhere even if only very small amounts
A. MIC break through the scavenging system.
B. HIC
C. SOHIC A. General
D. All of the above: A B. Localized
84. Cooling water corrosion is a concern with water-cooled C. Pitting
_________ and cooling towers in all applications across all D. Cracking: C
industries. 91. Corrosion in boiler feedwater and condensate return
systems is usually the result of dissolved gases, oxygen and
A. Pumps _________.
B. Vessels
C. Piping A. Carbon monoxide
D. Exchangers: D B. Carbon dioxide
85. ___________ cooling water outlet temperatures and/or process C. Material properties
side outlet temperatures tend to ___________ corrosion rates D. H²S: B
as well as fouling tendency. 92. Corrosion in boiler feedwater and condensate return
systems is usually the result of dissolved gases oxygen and
A. Increasing, decrease ________.
B. Decreasing, decrease
C. Decreasing, increase A. Carbon monoxide
D. Increasing, increase: D B. H²O
86. Copper base alloys form sulfide at ________ than carbon steel. C. Temperature
D. Carbon Dioxide: D
a. faster rates
b. lower temperatures
c. slower rates
d. higher temperatures: B
93. Corrosion of carbon steel and other alloys from their 100. Corrosion under insulation is more severe between _______
reaction with sulfur compounds in high temperature and _______.
environments is called _________. The presence of hydrogen
accelerates corrosion. A. 175°F, 212°F
B. 212°F, 350°F
A. Sulfide corrosion C. 250°F, 300°F
B. High temperature corrosion D. 25°F, 250°F: B
C. H²S corrosion 101. Cracking and fissuring caused by HTHA are _________ and
D. Sulfidation: D occur adjacent to pearlite (iron carbide) areas in carbon
94. Corrosion of the anode may be significantly higher ________ steels.
to the connection to the cathode, depending on the a. surface oriented
solution conductivity. b. subsurface
c. laminations
A. Parallel d. intergranular: d
B. Adjacent 102. Cracking can occur at low caustic levels if a concentrating
C. Diagonally mechanism is present. In such cases, caustic concentrations
D. Perpendicular: B of ______ ppm are sufficient to cause cracking.
95. Corrosion protection in the boiler is accomplished by laying
down and continuously maintaining a layer of _________. A. 50-100
B. 100-150
A. Manganese C. 150-200
B. Magnetite D. 200-250: A
C. Carbon monoxide 103. _________ cracking has been a major problem in coke drum
D. Carbonate: B shells.
96. __________ corrosion rates are found in a gas oil desulfurizers
and hydrocrackers than naphtha desulfurizers and A. Stress
hydrocrackers by a factor of almost "2". B. Carburization
C. Thermal fatigue
A. Lower D. Sulfide: C
B. Higher 104. Cracking of a metal due to stress relaxation during PWHT
C. Sulfidization or in service at elevated temperatures is called ___________. It
D. Hydrogen corrosion: B is most often found in heavy wall sections.
97. Corrosion rates of the anode can be high if there is a _______
anode to cathode ratio. A. Thermal cracking
B. Reheat cracking
A. Large C. Step-like cracking
B. Small D. None of the above: B
C. Severe 105. Cracking of dissimilar weld metals occurs in the ______ side
D. None of the above: B of a weld between an austenitic and a Ferritic material
98. Corrosion rates of the anode will be less affected if there is operating at high temperatures.
a _________ anode to cathode ratio.
A. Austenitic
A. Large B. Ferritic
B. Small C. Anodic
C. Severe D. Cathodic: B
D. None of the above: A 106. Cracking of dissimilar weld metals occurs in the ________ side
99. Corrosion under insulation becomes more severe at metal of a weld joining 300 Series SS and carbon steel.
temperatures between _______ and __________, where water is
likely to vaporize and insulation stays wet longer. A. Austenitic
B. Ferritic
A. 100°C, 121°C C. Both of the above
B. 92°C, 116°C D. None of the above: B
C. 114°C, 132°C
D. None of the above: A
107. Cracking susceptibility increases with _______ pH and 114. The creep threshold temperature for carbon steel is ________.
carbonate concentration.
A. 315°C
A. Increasing B. 371°C
B. Decreasing C. 426°C
C. Low D. 538°C: B
D. High: A 115. Damage due to ___________ is not visible and can only be
108. Cracks associated with brittle fracture will typically be observed by metallographic examination.
______.
A. Galvanic corrosion
A. Jagged B. Brittle fracture
B. Branching C. Cavitation
C. Straight D. Graphitization: D
D. Perpendicular: C 116. Damage from sigma phase appears in the form of _______.
109. Cracks connecting hydrogen blisters are referred to as
_________. A. Corrosion
B. Hardness
A. SOHIC C. Cracking
B. HIC D. Ductility: C
C. SCC 117. Deaerator cracking problems are usually evaluated off-line
D. None of the above: B at shutdowns of boilers. What inspection method is used?
110. Cracks that are typically straight, non-branching, and
devoid of any associated plastic deformation are likely a. Radiographic inspection.
associated with which type of failure? b. Wet fluorescence magnetic particle inspection.
c. Dye penetrant inspection.
A. Stress corrosion cracking d. Eddy current inspection.: B
B. Brittle fracture 118. Decarburization results in a ___________, which can be
C. Thermal fatigue confirmed by hardness testing.
D. Temper embrittlement: B
111. Creep and stress rupture is more likely in a _________ grained A. Hardness
material than a ______ grained material. B. Softness
C. Brittleness
A. Course, Fine D. Oxidizing: B
B. Fine, Course 119. Depending on condition of service, sulfidation corrosion is
C. Austenetic, Martensitic most often in the form of:
D. None of the above: A
112. Creep damage is found in high temperature equipment a. random grooving.
operating above the ________. Fired heater tubes and b. uniform thinning.
components, Catalytic reactors, FCC reactors and FCC c. heavy localized pitting.
fractionator and regenerator internals all operate in or d. unsystematic pitting.: B
near this. 120. Dew point corrosion can occur if the metal temperature is
below the dew point. The dew point of sulfuric acid is _______.
A. Transition range
B. MADT A. 280°F
C. Creep range B. 220°F
D. None of the above: C C. 310°F
113. The creep threshold temperature for 1¼, 2¼, 5 and 9 Cr is D. 190°F: A
__________. 121. The dew point of hydrochloric acid depends on the
concentration of hydrogen chloride. It is typically about
A. 600°F _______.
B. 700°F
C. 800°F A. 180°F
D. 1000°F: C B. 160°F
C. 130°F
D. 110°F: C
122. Different organisms thrive on different nutrients including 129. The endurance limit is usually about:
inorganic substances (Sulfur, H²S), and organic substances
(Hydrocarbons, Organic acids). In addition, all organisms A. 10-20% of a material's ultimate tensile strength
require a source of carbon, nitrogen and ____ for growth. B. 40-50% of a material's ultimate tensile strength
C. 10-20% of a material's yield strength
A. Oxygen D. 40-50% of a material's yield strength: B
B. Water 130. Equipment that is exposed to moving fluids and/or catalyst
C. Manganese are subject to erosion and erosion-corrosion.
D. Phosphorous: D What unit is most often damaged by gas borne catalyst
123. Dissimilar metal welds with a 300 Series stainless steel weld particles?
metal on a ferritic steel may also result in narrow region of
_______ at the toe of the weld, near the fusion line on the a. Desalting Unit.
ferritic side. b. Motor Oil Unit.
c. Crude and Vacuum Unit.
A. Ductility d. Fluid Catalytic Cracker.: D
B. Hardness 131. Equipment that is temper embrittled may be susceptible to
C. Cracking _________ during start-up and shutdown.
D. None of the above: B
124. Dissimilar weld metal cracking can be aggravated by A. Creep
_________. B. Thermal fatigue
C. Brittle fracture
A. Stress D. Stress fatigue: C
B. Pressure 132. Erosion-corrosion is a description for the damage that
C. Thermal cycling occurs when corrosion contributes to erosion by removing
D. Cyclic stresses: C protective films or scales, or by exposing the metal surface
125. Dissimilar weld metal cracking forms at the toe of the weld to further ________ under the combined action of corrosion-
in the heat affected zone of the _______ material. erosion.

A. Ferritic A. Stress
B. Austenitic B. Corrosion
C. Martensitic C. Oxidation
D. Both B and C: A D. None of the above: B
126. Dissimilar weld metal cracking occurs because the 133. Erosion-corrosion is best controlled by using __________
coefficients of thermal expansion between ferritic steel and/or altering the process environment to reduce
and 300 Series stainless steels differ by ______ or more. corrosivity.

A. 10% a. corrosion inhibitors

B. 15% b. wear plates
C. 20% c. hard-facing by weld overlays
D. 30%: D d. more corrosion-resistant alloys: D
127. The effects of hydrogen embrittlement __________ with 134. Exposure to high solution caustic can result in general
_________ temperatures. corrosion or high corrosion rates above ___________.

A. Increase, increasing A. 175°F

B. Decrease, decreasing B. 150°F
C. Increase, decreasing C. 125°F
D. Decrease, increasing: D D. 100°F: B
128. __________ eliminates the susceptibility of most common 135. The extent and depth of decarburization is a function of
steels to SCC. temperature and ________.

A. Preheat A. Pressure
B. High temperature B. Material properties
C. PWHT C. Exposure Time
D. All of the above: C D. Velocity: C
136. Fatigue cracks usually initiate on the surface at notches or 143. For carbon steel, common velocity limits are generally
___________ under cyclic loading. limited to ________ fps for rich amine and _________fps for lean
amine.
A. Branches
B. Laterals A. 8-10, 30
C. Stress concentrations B. 6-9, 15
D. Grinding marks: C C. 4-8, 10
137. A fatigue failure exhibits what type of "fingerprint" or D. 3-6, 20: D
appearance? 144. For furnaces, to prevent PASCC, keep the firebox heated
above the dew point to keep _________ from forming.
a. The failure exhibits a hash mark type of fingerprint that
radiates from the crack origin. A. Water
b. The failure exhibits a "clam shell" type of fingerprint that B. Acids
has concentric rings called "beach marks" . C. Moisture
c. The failure exhibits a wavy type of fingerprint that is D. Corrosion: B
random in nature. 145. For galvanic corrosion to take place, three condition must
d. The failure exhibits a ragged rough type of fingerprint met, presence of an electrolyte, two different materials or
that emanates from the failure point.: B alloys and _________.
138. A fatigue fracture is brittle and the cracks are most often
________. A. a cathode
B. a anode
A. Parallel C. an electrical connection
B. Transgranular D. None of the above: C
C. Intergranular 146. Formation of a metallurgical phase known as sigma phase
D. Transverse: B results in a loss of ________ in some stainless steels as a
139. Fatigue will not occur in carbon steel if stresses are below result of high temperature exposure.
the:
A. Ductility
A. Transition limit B. Fracture toughness
B. Endurance limit C. Embrittlement
C. Hardening limit D. None of the above: B
D. Speed limit: B 147. Formation of sigma phase in austenitic stainless steels can
140. Ferritic stainless steels are usually not used in ________ also occur in a few hours, as evidenced
applications. by the known tendency for sigma to form if an austenitic
stainless steel is subjected to a post weld
A. Non-pressure boundary heat treatment at _______.
B. Pressure boundary
C. High temperature A. 1150°F
D. Low temperature: B B. 1275°F
141. For 5Cr-0.5Mo, what is the threshold temperature for creep? C. 1100°F
D. 1325°F: B
A. 500°F 148. A form of corrosion caused by living organism such as
B. 800°F bacteria, algea or fungi is ___________.
C. 600°F
D. 700°F: B A. HIC
142. For a specific material, HTHA is dependent on temperature, B. SOHIC
hydrogen partial pressure, time and _____________. C. MIC
D. None of the above: C
A. Stress
B. Pressure
C. Velocity
D. Alloy composition: A
149. A form of corrosion that can occur at the junction of 155. Foul smelling water may be sign of fouling and/or ________.
dissimilar metals when they are joined together in a suitable
electrolyte is _______. A. MIC
B. HIC
A. Galvanic corrosion C. SOHIC
B. Anodic corrosion D. All of the above: A
C. Cathodic corrosion 156. Galvanized steel components should not be welded to
D. All of the above: A _______ due to LME.
150. A form of fatigue cracking in which cracks develop under
the combined effects of cyclic loading and corrosion is A. 300 Series SS
called _________. Cracking often initiates at stress B. 400 Series SS
concentrations such as a pit in the surface. C. Carbon Steel
D. Duplex SS: A
A. Cyclic cracking 157. General or localized corrosion of carbon steels and other
B. Corrosion cracking metals caused by dissolved salts, gases, organic compounds
C. Stress fatigue or microbiological activities is called_______.
D. Stress cracking: B
151. A form of mechanical fatigue in which cracks are produced A. Flue Gas Corrosion
as a result of dynamic loadings is ________. B. Atmospheric corrosion
C. Cooling water corrosion
A. Spheroidization D. None of the above
B. Vibration-induced cracking E. All of the above: C
C. Fatigue cracking 158. General or localized corrosion of carbon steels and other
D. Stress cracking: B metals caused by dissolved salts, gases, organic compounds
152. A form of thermal cracking, _________, can occur when high or microbiological activity is called ______.
nonuniform thermal stresses develop over a relatively short
period of time in a piece of equipment due to differential A. Cooling water corrosion
expansion and contraction. B. Oxidation
C. MIC
A. Thermal expansion D. None of the above: A
B. Thermal stress 159. Geometry, stress level, _________ and material properties are
C. Thermal shock the predominate factors in determining the fatigue
D. Linear expansion: C resistance of a component.
153. For pressure vessels, inspection should focus on welds of
________ operating in the creep range. A. Temperature
B. Pressure
A. CrMo alloys C. Velocity
B. Carbon steel D. Number of cycles: D
C. Stainless steel 160. Geometry, stress level, number of cycles and ________ are
D. Low hydrogen electrodes: A the predominate factors in determining the fatigue
154. For some materials such as titanium, carbon steel and low resistance of a component.
alloy steel, the number of cycles to fatigue fracture
decreases with __________ until an endurance limit is reached. A. Temperature
Below this endurance limit, fatigue cracking will not occur, B. Material properties
regardless of the number of cycles. C. Pressure
D. Velocity: B
A. Temperature increases
B. Stress amplitude
C. Pressure decreases
D None of the above: B
161. The grain size has an important influence on the high 167. Hardness levels above _________ are highly susceptible to
temperature ductility and on the reheat cracking hydrogen stress cracking (HF). Time-to-failure decreases as
susceptibility. A ___________ grain size results in ________ ductile the hardness increases.
heat affected zones, making the material more susceptible
to reheat cracking. A. 225 BHN
B. 237 BHN
A. Large, more C. 241 BHN
B. Small, less D. 247 BHN: B
C. Large, less 168. ____________ has been a major problem on coke drum shells.
D. Small, more: C
162. Graphitization can be prevented by using chromium A. Thermal fatigue
containing low alloys steels for long-term exposure above B. Stress cracking
__________. C. Erosion
D. Temper embrittlement: A
A. 650°F 169. HCl acid corrosion is found in several units, especially _______
B. 700°F and _________ units, hydroprocessing units and catalytic
C. 750°F reformer units.
D. 800°F: D
163. The graphitization rate ___________ with increasing A. Amine, crude
temperature. B. Crude, Alkylation
C. Vacuum, Amine
A. Increases D. Crude, Vacuum: D
B. Decreases 170. Heat treatment can have a significant effect on the
C. Stops toughness and hence fatigue resistance of a metal. In
D. Proceeds: A general, _________ grained microstructures tend to perform
164. ________ greatly increase the probability and severity of better then _________ grained.
blistering, HIC and SOHIC damage.
A. Fine, Course
A. Acids B. Austenetic, Martensitic
B. Caustics C. Course, Fine
C. Amines D. Martensitic, Austenetic: A
D. Cyanides: D 171. Higher _________ containing alloys are used for improved
165. A hard, brittle surface layer will develop on some alloys resistance to naphthenic acid corrosion.
due to exposure to high temperature process streams
containing high levels of nitrogen compounds such as A. Chromium
ammonia or cyanides, particularly under reducing B. Carbon
conditions, is called _________. C. Molybdenum
D. All of the above: C
A. Carburization 172. High strength, low alloy steels such as A193-B7 bolts and
B. Spheroidization compressor parts are susceptible to hydrogen stress
C. Nitriding cracking. A193-B7M Bolts are susceptible if __________.
D. None of the above: C
166. Hardness is primarily an issue with SSC. Typical low A. Exposed
strength carbon steel should be controlled to produce B. Overtorqued
weld hardness less than _________. C. Double nutted
D. None of the above: B
A. 225 BHN 173. High strength steels are susceptible to LME when they
B. 237 BHN come in contact with molten ___________.
C. 200 BHN
D. 240 BHN: C A. Cadmium
B. Zinc
C. Lead
D. Both A and C: D
174. High temperature H² / H²S corrosion damage is minimized 181. Hydrochloric acid corrosion is a general and localized
by using alloys with high ___________ content. corrosion and is very aggressive to most common materials
on construction. Damage in refineries is often associated
A. Carbon with dew point corrosion in which vapors containing _______
B. Molybdenum and hydrogen chloride condense from the overhead stream
C. Chromium of a distillation, fractionation, or stripping tower.
D. Stainless: C
175. High temperature hydrogen attack results from exposure to A. O²
hydrogen at elevated temperature and pressures. The B. O
hydrogen react with _________ in steel to produce _______, C. H²O
which cannot diffuse through steel. The loss of carbides D. CO²: C
causes an overall loss in strength. 182. Hydrogen blisters may form as surface bulges on the ID,
the OD on within the wall thickness of a pipe or pressure
A. Carbides, oxygen vessel. Blistering occurs from hydrogen generated by
B. Alloys, hydrogen dioxide __________, not hydrogen gas from the process stream.
C. Carbides, methane
D. Hydrogen dioxide, H²S: C A. H²S
176. How do you mitigate brittle fracture of new equipment. B. Corrosion
a. Use only 400 series stainless steels. C. Hydriding
b. Use only 300 series stainless steels. D. Sulfur: B
c. Use material specifically designed for low temperature 183. Hydrogen blisters may form at many different depths from
operation per ASME B&PV Code. the surface of the steel, in the middle of the plate or near a
d. Use material designed for high temperature operation weld. In some cases, neighboring or adjacent blisters that
per ASME B&PV Code.: C are at slightly different depths (planes) may develop cracks
177. How is the effectiveness of treatment monitored in cooling that link them together. Interconnecting cracks between
water systems? the blisters often have a ________ appearance.
a. using AE.
b. measuring biocide residuals. A. Crescent
c. using velocity ratio technique. B. Eyebrow
d. using ACFM technique.: B C. Step Like
D. Jagged: C
178. How many mils per year would you expect a carbon steel
line to lose if exposed to a marine environment? 184. Hydrogen permeation or diffusion rates have been found to
be minimal at pH __________ and increase at both higher and
a. 20 mpy lower pH's.
b. 15 mpy
c. 10 mpy A. 4
d. 5 mpy: A B. 5
C. 6
179. HTHA is dependent on temperature, hydrogen partial
D. 7: D
pressure, time and ________.
185. Hydrogen stress cracking is the same mechanism that is
A. Pressure responsible for sulfide stress corrosion cracking in wet H²S
B. Stress environments except that HF acid is generating the ________.
C. Yield
D. Tensile strength: B A. Sulfide
B. Caustic
180. Hydriding of titanium is a metallurgical phenonemon in
C. Hydrogen
which hydrogen diffuses into the titanium and reacts to
D. Water: C
form an embrittling phase. This can results in a complete
loss of ________ with no noticeable sign of corrosion or loss 186. Hydrogen stress cracking is the same mechanism that is
of thickness. responsible for sulfide stress corrosion cracking in wet H²S
environments except that HF acid is generating the ________.
A. Strength
B. Ductility A. Sulfide
C. Carbides B. Corrosion
D. Hardness: B C. Hydrogen
D. None of the above: C
187. If the BHN is 400-500 it may indicate __________. 193. Increasing chromium content in the alloy improves
resistance to sulfidation. However, there is little
A. Carburization improvement with increasing chromium content until about
B. Hydriding ______ Cr.
C. Temper embrittlement
D. Caustic embrittlement: B A. 3-5
188. If weld repairs are required, the effects of temper B. 5-7
embrittlement can be temporarily reversed (de-embrittled) C. 7-9
by heating at __________ for 2 hours per inch of thickness and D. 9-12: C
rapidly cooling to room temperature. 194. Increasing the chromium in steels offers no major
improvement in resistance to CO² corrosion until a minimum
A. 1000°F of _________ is reached.
B. 1150°F
C. 1200°F A. 9%
D. 1250°F: B B. 12%
189. If wet electrodes or high moisture content flux is used, C. 5%
___________ can be charged into the steel resulting in delayed D. 7%: B
cracking. 195. In design and fabrication, it is advisable to avoid sharp
changes in cross section, such as short radius fillets or
A. Atomic hydrogen undercut that can give rise to _________.
B. Hydrogen
C. Oxygen Long-seam welds are particularly susceptible to reheat
D. H²O: B cracking due to mismatch caused by fit up problems.
190. If wet electrodes or high moisture content flux weld
electrodes are used to weld carbon steel, hydrogen can be A. Stress concentrations
charged into steel resulting in ________________. B. Cracking
C. Circumferential stress
A. Reduced tensile strength D. All of the above: A
B. Loss of ductility 196. In fired heater tubes, dissimilar weld metal cracking forms
C. Delayed cracking primarily on the _________ of the material.
D. All of the above: C
191. Improved resistance to erosion is usually achieved through A. Outside
increasing substrate ________ using harder alloys, hard facing B. Inside
or face-hardening treatment. C. Welds
D. All of the above: A
A. Composition 197. In general, the resistance of carbon steel and other alloys
B. Stress to high temperature corrosion is determined by the ________
C. Hardness content of the material.
D. None of the above: C
192. In a pump, the difference between the actual pressure, or A. Molybdenum
head, of a liquid available (measured on the suction side) B. Chromium
and the vapor pressure of that liquid is called Net Positive C. Carbon
Suction Head (NPSH) available. The minimum head required D. All of the above: B
to prevent cavitation with given liquid at a given flow rate is 198. In general, the resistance of iron and nickel based alloys to
called Net Positive Suction Head _________. Inadequate NPSH sulfidation is determined by the _________ content of the
can result in cavitation. material.

A. Surplus A. Chromium
B. Required B. Carbon
C. Reserve C. Molybdenum
D. None of the above: B D. Alloying: A
199. In HF Service, carbon steel form a protective _______ scale in 205. In most cases, brittle fracture occurs only at temperatures
dry concentrated acid. Loss of the protective scale through ________ the Charpy impact transition temperature.
high velocities or turbulence will result in greatly
accelerated corrosion rates. A. Above
B. Below
A. Chloride C. Around
B. Fluoride D. Inside: B
C. Iron sulfide 206. In order for PASCC to occur the material must be ___________.
D. Iron oxide: B
200. In HF service, carbon steel forms a protective fluoride A. PWHT
scale in dry concentrated acid. Loss of the protective scale B. Non-PWHT
through high _________ or turbulence will result in greatly C. Sensitized
accelerated corrosion rates. D. Austenetic: C
207. In order to minimize and prevent amine SCC, PWHT all
A. Temperature carbon steel welds in accordance with API RP _________.
B. Pressure
C. Velocities A. 751
D. None of the above: C B. 912
201. In HF service, carbon steel operating above ________ should C. 510
be closely monitored for loss on thickness and may need D. 945: D
to be upgraded to Alloy 400. 208. In piping and equipment, creep cracking can occur where
high metal temperatures and _________ occur together. Creep
A. 150°F cracking, once initiated, can progress rapidly.
B. 175°F
C. 160°F A. Pressures
D. 200°F: A B. Stress risers
202. ___________ injection downstream of the desalter is another C. Velocities
common method used to reduce the amount of HCl going D. None of the above: B
overhead. 209. In pressure containing equipment, SOHIC and SCC damage
is most often associated with ________.
A. Hydrogen
B. Nitrogen A. Internals
C. Water B. Weldments
D. Caustic: D C. Branches
203. In most cases, brittle fracture occurs only at temperatures D. None of the above: B
below the Charpy impact _______________ temperature, the 210. Inspecting for high-cycle fatigue can be difficult since:
point at which the toughness of the material drops off
sharply. A. The cracks are extremely tight
B. Predicting the location of cracking is difficult
a. failure C. Once the crack begins, only a few cycles are needed for
b. transition the crack to lead to failure.
c. critical D. Often the equipment is vibrating making non-destructive
d. stable: B evaluations difficult.: C
204. In most cases, brittle fracture occurs only at temperatures 211. Inspection for wet H²S damage generally focuses on ________
below the Charpy impact transition temperature. Steel and _______.
cleanliness and __________ have a significant influence on
toughness and resistance to brittle fracture. A. Weld seams, Nozzles
B. Trays, Weld Seams
A. Alloy composition C. Nozzles, trays
B. Tensile strength D.None of the above: A
C. Grain Size
D. Pressure: C
212. An inspector notes that there are cracks in the brick 218. _____________ is a change in the microstructure of certain
fireproofing of a column supporting a vessel on a FCC unit. carbon steels and 0.5Mo steels after long-term operation
An inspection hole is opened to check the condition of the in the 800°F to 1100°F range that may cause a loss in
column. Heavy rust scale is present and the inspector strength, ductility and/or creep resistance.
requires the entire column to be stripped. Severe pitting to
holes and serious thinning of the column is found. What A. Embrittlement
type of corrosion would this be? B. Carburization
C. Graphitization
a. Heavy erosion from catalyst. D. Sensitization: C
b. Chloride attack. 219. ___________ is a change on the microstructure of steels after
c. Normal weathering of the column. exposure in the 850°F to 1400°F range, where the carbide
d. CUI (corrosion under insulation).: D phases in carbon steels are unstable and may agglomerate
213. In susceptible materials, Primary factor that affects sigma from their normal plate-like appearance.
phase formation is the ___________ at elevated temperatures.
A. Carburization
A. Time of exposure B. Spheroidization
B. Pressure C. Graphiding
C. Stress D. 885°F embrittlement: B
D. Velocity: A 220. ________ is a form of carbon that may promote carburization,
214. In vessels and piping, creep cracking can occur where high particularly during decoke cycles where temperatures
metal temperatures and ________ occur together. exceed the normal operating temperatures.

A. Pressures A. Carbonic acid

B. Stress Concentrations B. Coke
C. Velocities C. Crude oil
D. None of the above: B D. None of the above: B
215. In what type of environment would atmospheric corrosion 221. ___________ is a form of carburization resulting in accelerated
be most severe? localized pitting which occurs in carburizing gases and/or
process streams containing carbon and hydrogen. Pits
a. Marine environments, and moist polluted industrial usually form on the surface and may contain soot or
environments. graphite dust.
b. Desert environments, and cold dry rural environments.
c. Areas exposed to the morning sun and prevailing winds. A. Hydrate corrosion
d. Far north environments with maximum exposure to cold B. Carbide corrosion
and snow.: A C. Spheroidization
216. __________ is accelerated high temperature wastage of D. Metal dusting: D
materials that occurs when contaminants in the fuel form 222. ___________ is a form of cracking that results when certain
deposits and melt on the metal surfaces. molten metals come in contact with specific alloys.
Cracking can be very sudden and brittle in nature.
A. Spheroidization
B. Dealloying A. SCC
C. Fuel ash corrosion B. LME
D. None of the above: C C. AET
217. ____________ is a change in the microstructure of certain D. SOHIC: B
carbon steels and 0.5 Mo steels after long term operation 223. ___________ is a form of damage found mostly in older vintage
in the 800°F to 1100°F range. carbon steels and C-0.5 Mo low alloy steels under the
combined effects of deformation and aging at an
A. Graphitization intermediate temperature.
B. Softening
C. Temper Embrittlement A. Spheroidization
D. Creep: A B. Thermal fatigue
C. Strain aging
D. None of the above.: C
224. _______________ is a form of environmental cracking that can 230. __________ is most likely found in hard welds and heat
initiate on the surface of high strength low alloy steel and affected zones and in high strength components.
carbon steels with highly localized zones of high hardness
on the weld metal and HAZ as a result of exposure to A. SOHIC
aqueous HF acid service. B. HIC
C. Carburization
A. Sulfide stress cracking D. SSC: D
B. Hydrogen stress cracking 231. ____________ is most likely found on hard weld and heat-
C. Caustic stress cracking affected zones and in high strength components.
D. Hydrogen induced cracking: B
225. ___________ is a form of stress corrosion cracking normally A. HIC
occurring during shutdowns, startups or during operation B. SSC
when air and moisture are present. Cracking is due to sulfur C. SOHIC
acids forming from sulfide scale, air and moisture on D. Blistering: B
sensitized stainless steel. 232. ___________ is often found in piping and equipment that
handles caustic, including H²S and mercaptan removal units,
A. Caustic SCC as well as equipment that handles caustic, including H²S and
B. Chloride SCC mercaptan removal unit, as well as equipment that uses
C. Polythionic acid SCC caustic for neutralization in sulfuric acid and HF acid units.
D. None of the above: C
226. _____________ is a form or erosion caused by the formation A. Carburization
and instantaneous collapse of innumerable tiny vapor B. Sulfide corrosion
bubbles. C. Caustic embrittlement
D. Hydrogen cracking: C
A. Condensate corrosion 233. ____________ is similar to HIC but is a potentially more
B. Cavitation damaging form of cracking which appears as arrays of
C. Dew-point corrosion cracks stacked on top of each other. The result is a through
D. Atmospheric corrosion: B thickness crack that is perpendicular to the surface and is
227. _________ is a loss in toughness due to metallurgical change driven by high levels of stress.
that can occur in alloys containing a ferrite phase, as a
result of exposure in the temperature range 600°F to A. MIC
1000°F. B. SOHIC
C. Sulfuric SCC
A. Caustic embrittlement D. None of the above: B
B. Notch toughness 234. ___________ is surface initiated cracks caused by
C. 885°F embrittlement environmental cracking of 300 Series SS and some nickel
D. Ductile embrittlement: C based alloys under the combined action of tensile stress,
228. ____________ is a mechanical form of degradation that occurs temperature and aqueous chloride environment. The
when a component is exposed to cyclical stresses for a presence of dissolved oxygen increases the propensity for
extended period, often resulting in sudden unexpected cracking.
failure.
A. SSC
A. Stress fatigue B. SOHIC
B. Mechanical fatigue C. CI SCC
C. Thermal fatigue D. HIC: C
D. Cyclic fatigue.: B 235. ___________ is the main concern during start-up, shutdown
229. ___________ is a selective corrosion mechanism in which one or and/or hydro testing for equipment/piping operating at
more constituents of an alloy are preferentially attacked elevated temperatures. This event can also occur in an auto
leaving a lower density often porous structure. refrigeration event in units processing light hydrocarbons.

A. Phenol corrosion A. Stress fracture

B. Dealloying B. Carburization
C. Carburization C. Spheroidization
D. Preferentially weld attack: B D. Brittle fracture: D
236. ___________ is the primary alloying agent that affects 243. It is generally accepted that stresses approaching _________
resistance to oxidation. are required for SCC to occur so that thermal stress relief is
effective in preventing caustic SCC.
A. Chromium
B. Molybdenum A. MAWP
C. Silicon B. Yield
D. Aluminum: A C. Creep range
237. ________ is the reduction in toughness due to metallurgical D. Critical: B
change that can occur in some low alloy steel as a result of 244. Key factors affecting thermal fatigue are the magnitude of
long-term exposure in the temperature range of about the_______________ and the ____________.
650°F to 1100°F.
a. temperature; rate (speed of rise)
A. Hardening b. equipment size; complexity (intricacy of construction)
B. Graphitization c. stress loading; size (increase, decrease of loads)
C. Spheroidization d. temperature swing; frequency (number of cycles): D
D. Temper embrittlement: D 245. Key factors affecting thermal fatigue are the magnitude of
238. _________ is the result of cyclic stress caused by variation in the temperature and the _________.
temperature.
A. Number of cycles
A. Creep B. Pressure
B. Thermal fatigue C. Stress
C. Cyclic cracking D. Alloy composition: A
D. Stress corrosion cracking: B 246. Lean amine is generally not corrosive because they either
239. ___________ is the result of cyclic stresses caused by variation have low conductivity and/or high pH. Corrosion rates
in temperature. increase with increasing temperature, particularly in rich
amine service. Temperatures above ___________ can result in
A. Cyclic cracking acid gas flashing and severe localized corrosion.
B. Stress cracking
C. Stress fatigue A. 170°F
D. Thermal fatigue: D B. 190°F
240. ______ is the sudden rapid fracture under stress (residual or C. 220°F
applied) where the material exhibits little or no evidence of D. 240°F: C
ductility or plastic deformation. 247. The level of creep damage is a function of the material and
the coincident _______ level at which the creep deformation
A. Thermal fatigue occurs.
B. Thermal shock
C. Brittle fracture A. Pressure/Temperature
D. Stress fracture: C B. Pressure/Stress
241. _________ is usually found in aqueous environments or C. Temperature/Stress
services where water is sometimes or always present, D. None of the above: C
especially where stagnant or low-flow conditions allow the 248. The "L" grade of stainless steel will sensitize if exposed
growth of microorganisms. more than several hours above _________ or long term above
_________.
A. MIC
B. HIC A. 1200°F, 800°F
C. SOHIC B. 1000°F, 600°F
D. None of the above: A C. 1000°F, 750°F
242. ___________ is when oxygen reacts with carbon steel and D. 1100°F, 800°F: C
other alloys at high temperature converting the metal to 249. Liquid metal embrittlement can occur if 300 Series SS
oxide scale. comes in contact with molten __________.

A. High temperature corrosion A. Copper

B. Oxidation B. Mercury
C. Dealloying C. Zinc
D. Thermal fatigue: B D. Lead: C
250. Localized corrosion due to the concentration of caustic or 257. The major factors affecting high temperature sulfidation are
alkaline salts that usually occurs under evaporative the temperature, the presence of hydrogen, the H²S
conditions is ____________. concentration and the _________.

A. Carbonate corrosion A. Pressure

B. Caustic corrosion B. Stress
C. Alkaline Corrosion C. Alloy composition
D. None of the above: B D. Velocity: C
251. A loss in ductility of high steels due to penetration of 258. Major factors affecting sulfidation are alloy composition,
atomic hydrogen can lead to brittle cracking hydrogen temperature and _________.
embrittlement. Which of the following materials is
susceptible to HE. A. Time
B. Stress
A. Carbon Steel C. Concentration of hydrogen
B. 400 Series SS D. Concentration of Sulfur: D
C. low alloy steel 259. Major factors affecting sulfidation are alloy composition,
D. All of the above: D temperature and concentration of _________ corrosive
252. The loss in strength from spheroidization (Softening) is compounds.
usually accompanied by a(n) _________ in ductility, which
allows for deformation at stress concentration. a.water
b. hydrogen
A. Increase c. sulfur
B. Decrease d. ammonia: C
C. Reduction 260. Many thermal fatigue cracks are filled with:
D. Yield: A
253. Low alloy steels contain a maximum of ______ chrome. A. chlorides
B. hydroslime
A. 5% C. oxides
B. 6% D. sulfides: C
C. 7.5% 261. ________ material sections also have a ________ resistance to
D. 9%: D brittle fracture due to higher constraint, which increases
254. Low Creep ductility is ______ prevalent at the lower triaxial stresses at the crack tip.
temperatures in the creep range. Or low stresses in the
upper creep range. A. Thinner, lower
B. Thicker, Lower
A. More C. Thinner, Higher
B. Less D. Thicker, Higher: B
C. Equally 262. Mechanical fatigue can cause cracks that initiate from the
D. None of the above: A surface and often form a:
255. Low creep ductility is _________ severe in high tensile
strength materials and welds. A. Clam shell appearance
B. Snail shell appearance
A. More C. Turtle shell appearance
B. Less D. None of the above: A
C. Usually 263. Mechanical fatigue is caused by:
D. Not: A
256. The major factors affecting high temperature sulfidation are A. cyclic stresses occurring over a long period of time
the temperature, the presence of hydrogen, the B. Higher than average stresses at high temperatures
concentration of H²S and the __________. C. Constant stresses occurring at low temperatures
D. Cyclic operating conditions of bird poop, then rain etc.: A
A. Alloy content
B. Velocity
C. Pressure
D. Water content: A
264. Metal dusting is preceded by ________ and is characterized 271. Most brittle failures appear as:
by rapid metal wastage.
A. Branched cracking
A. Decarburization B. Intergranular cracking
B. Carburization C. Ductile tears
C. Graphitization D. Cleavage: D
D. None of the above: B 272. Most Brittle failures occur:
265. Metallic components form a surface _________ when exposed
to sulfur compounds. This may react with air (oxygen) and A. Below the impact transition temperature
moisture to form sulfur acids (polythionic acid). B. On thinner materials
C. On "Clean" steel
A. Oxide D. While in operation at elevated temperatures: A
B. Sulfide scale 273. The most common method used for monitoring
C. Sulfate scale underground structures is measuring the structure to soil
D. Caustic scale: B __________ using dedicated reference electrodes near the
266. MIC is often characterized by _________ within pits in carbon structure.
steel.
A. Resistivity
A. Oxide B. Corrosiveness
B. Tubercles C. Potential
C. Worm Holes D. Electrolyte: C
D. Cup shaped pits: D 274. The most important factors affecting graphitization are the
267. MIC is often found in _________, bottom water storage tanks, chemistry, stress, temperature and ______.
piping with stagnant or low flow and piping in contact with
some soils. A. Velocity
B. Time at exposure
A. Vessels C. Pressure
B. Heat exchangers D. Ductility: B
C. Drums 275. NAC may be found in hot hydrocarbon streams downstream
D. All of the above: B of the crude and vacuum units, ___________ any hydrogen mix
268. A minimum of ________ to _______ molybdenum is needed in point.
alloy to resist naphthenic acid corrosion.
A. Upstream of
A. 2%, 3% B. Downstream of
B. 1½%, 2½% C. Adjacent to
C. 2%, 2½% D. Around: A
D. 1%, 2%: C 276. Naphthenic acid corrosion is a form of high temperature
269. Mitigation of CUI is best achieved by __________. corrosion that occurs primarily in crude and vacuum units
and downstream units that process certain fractions that
A. A properly documented inspection program. contain naphthenic acid. Which of the following materials is
B. A properly installed insulation system. susceptible to naphthenic acid corrosion?
C. A properly applied coating system
D. A properly documented NDE program.: C A. Carbon steel
270. The more noble material, called the __________, is protected B. 300 Series SS
by sacrificial corrosion of the more active material, called C. 400 Series SS
____________. The more active metal corrodes at a higher rate D. All of the above: D
than it would if it were not connected tot he more noble 277. Naphthenic acid corrosion is most severe in __________ flow;
metal. in areas of high velocity or turbulence and in distillation
towers where hot vapors condense to form liquid droplets.
A. Anode, Cathode
B. Cathode, Anode A. Single phase
C. Alpha, Omega B. Two phase
D. None of the above: B C. Three phase
D. Negative phase: B
278. Naphthenic acid is ______ by catalytic reactions on 285. __________ of the amine system is the most effective way to
downstream hydro processing and FCC units. prevent amine corrosion.

A. Enhanced A. Proper concentration

B. Destroyed B. Proper operation
C. Concentrated C. Proper design
D. Diluted: B D. Proper startup: B
279. Nickel based alloys usually contain _______ nickel. 286. Once cracking from LME has occurred, grinding out the
affected area ______ an acceptable fix.
A. >30%
B. >20% A. Is
C. >10% B. Is not
D. >12%: A C. Can be
280. Nitriding begins above _________ and becomes severe above D. Cannot be: B
________. 287. Oxidation of carbon steel begins to become significant
above ________.
A. 500°F, 800°F
B. 600°F, 900°F A. 800°F
C. 800°F, 1000°F B. 900°F
D. 700°F, 1100°F: B C. 1000°F
281. Nitriding is usually confined to the surface of most D. 1100°F: C
components and will have a dull, ________ appearance. In 288. Oxygen and iron in the water injected into reactor effluent
more advanced stages, the material will exhibit very hard can lead to __________ corrosion and fouling.
surface hardness.
A. Increased
A. Gray B. Decreased
B. Black C. Substantial
C. Brown D. Minimal: A
D. White: A 289. Permanent deformation occurring at relatively low stress
282. Nitriding layers are magnetic. Therefore, _________ should be levels as a result of localized overheating is called _______.
checked for magnetism as an initial screening for nitriding.
A. Stress cracking
A. 300 Series SS B. Brittle fracture
B. 400 Series SS C. Temper embrittlement
C. Duplex SS D. Stress rupture: D
D. Low alloy steel.: A 290. Phosphoric acid corrosion is usually found in ________ areas.
283. Non-stressed relieved _________ is susceptible to stress
corrosion cracking when in contact with moist HF vapors in A. High velocity
the presence of oxygen. B. Low Velocity
C. High temperature
A. Carbon steel D. Low temperature: B
B. Alloy 400 291. The presence of _________ can destabilize the scale and turn
C. 300 Series SS it into a non protective scale.
D. 400 Series SS: B
284. __________ of a component is the most important factor in A. H²S
determining a components resistance to mechanical B. O²
fatigue. C. H²
D. H²O: D
A. Design
B. Temperature
C. Stress
D. Pressure: A
292. The presence of _______ in H²S streams increases the 299. Protection in a boiler from boiler feed water corrosion is
severity of high temperature sulfide corrosion at accomplished by:
temperature above about 500°F
A. Injecting chlorines to kill microbiological bugs
A. Amine B. Injecting caustic to lower the pH to <4.0
B. Hydrogen C. Lowering solids content in boiler feed water to less than
C. Sulfides 50 ppm.
D. All of the above: B D. Maintaining a protective corrosion layer of magnetite
293. The presence of what other element increases the (Fe304): D
propensity for CI SCC cracking? 300. PWHT is _____________ in preventing caustic SCC.

a. Carbon dioxide. A. Effective

b. Oxygen. B. Not effective
c. Carbon monoxide. C. Not practical
d. Nitrogen.: B D. None of the above: A
294. Preventative measures to minimize the potential for brittle 301. A quick test for embrittlement from _________ is a bend test
fracture in existing equipment are limited to controlling or crush test. Unaffected material will be crushed in a
________ and _________, minimizing pressure at ambient ductile fashion while embrittled components will crack with
temperatures during start-up and shutdown and periodic no signs of ductility.
inspections at high stress locations.
A. Titanium Hydriding
A. Temperature, stress B. Temper embrittlement
B. Stress, pressure C. Caustic embrittlement
C. Velocity, stress D. None of the above: A
D. Temperature, pressure: D 302. The rate of creep deformation is a function of the material,
295. Primarily hot-wall piping and equipment in the following load and temperature. The rate of damage is sensitive to
units can be affected by graphitization. FCC, catalytic both load and temperature. Generally, an increase of about
reformer and ________. _____ or an increase of _________ on stress can cut the
remaining life in half.
A. Hydrotreater
B. Hydrocracker A. 25°F, 15%
C. Coker B. 50°F, 10%
D. Alky: C C. 50°F, 15%
296. The primary factors affecting high temperature oxidation D. 25°F, 10%: A
are metal temperature and ______. 303. Refractory anchor material must be compatible with the
_________ of the base metal.
A. Pressure
B. Alloy composition A. Composition
C. Stress B. Welding
D. Oxygen: B C. Thermal coefficient
297. A prime location for erosion is: D. Ductility: C
304. Refractory anchors must be resistant to _________ in high
A. In catalyst piping temperature services.
B. Downstream of a gate valve
C. Any superheated steam piping A. Thermal fatigue
D. Upstream of a pump: A B. Thermal cracking
298. Proper application of ________ will control but not eliminate C. Stress cracking
microbes that cause MIC so that continued treatment is D. Oxidation: D
necessary. 305. Refractory lined equipment should be designed for
erosion, thermal shock and ________.
A. Ozone
B. Caustic A. Thermal fatigue
C. Biocides B. Thermal expansion
D. None of the above: C C. Thermal contraction
D. All of the above: B
306. The regenerator reboiler and the regenerator are areas 313. SCC usually occurs at pH values above two(2). SCC
where the temperature and ________ of the amine stream are tendency __________ toward the alkaline pH region.
the highest and can cause significant corrosion problems.
A. Increases
A. Pressure B. Decreases
B. Stress C. Stabilizes
C. Turbulence D. None of the above: B
D. Concentration: C 314. Sensitization occurs in the _________ to ________ range.
307. Regular and controlled carbon grades of stainless steels
such as types 304/304H and 316/316H are particularly A. 800°F, 1400°F
susceptible to sensitization in the weld HAZ. Low carbon "L" B. 750°F, 1500°F
grades are less susceptible and usually can be welded C. 600°F, 1120°F
without sensitizing. The "L" grades will not sensitize D. 1000°F, 1750°F: B
provided long term operating temperatures do not exceed 315. The severity of hydrochloric acid corrosion _______ with _______
about ________. HCI concentration and increasing temperatures.

A. 700°F A. Decreases, decreasing

B. 750°F B. Increases, increasing
C. 800°F C. Decreases, increasing
D. 900°F: B D. Increases, decreasing: B
308. Reheat cracking is most frequently observed in __________ 316. Short term overheating is a permanent deformation
grained sections of a heat-affected zone. occurring at relatively ________ stress levels as a result of
localized overheating. This usually Results in bulging and
A. Course failure by stress rupture.
B. Fine
C. Dense A. Low
D. Treated: A B. High
309. The removal of a materials protective scale by impacting C. Even
materials is called: D. None of the above: A
317. Sigma phase in welds can be minimized by controlling
A. Erosion ferrite in the range of ___________ for Type 347 SS
B. Erosion-corrosion
C. Erosion or erosion-corrosion A. 3%-5%
D. IPRSC (imparting particle removal of scale corrosion): B B. 5%-7%
310. The removal of surface material by impacting materials is C. 7%-9%
called: D. 5%-9%: D
318. Sigma phase occurs in Ferritic, martensitic, austenitic and
A. Erosion duplex stainless steel when exposed to temperatures in the
B. Erosion-corrosion range of _________.
C. Erosion or erosion-corrosion
D. IPC (imparting particle corrosion): A A. 538°C - 927°C
311. Resistance to sulfidation increases as the : B. 614°C - 918°C
C. 676°C - 760°C
A. Chromium content in the material increases D. 584°C - 840°C: A
B. Nickel content in the material increases 319. Sigma phase occurs in Ferritic, martensitic, austenitic and
C. Material's tensile strength decreases duplex stainless steel when exposed to temperatures in the
D. Material's tensile strength increases: A range of _________.
312. SCC tendency __________ towards the alkaline pH region.
A. 850F - 1250F
A. Decreases B. 1000F - 1700F
B. Increases C. 950F - 1500F
C. Remains constant D. 800F - 1500F: B
D. Varies: A
320. The signature mark of a fatigue is a _______ type fingerprint 327. Soil corrosion appears as external thinning with localized
that has concentric rings. losses due to _______.

A. Eyebrow A. Resistivity
B. Half-moon B. Pitting
C. Radii C. General corrosion
D. Clam Shell: D D. Potential: B
321. ___________ significantly increases the probability and severity 328. Soil corrosion of carbon steel can be minimized through
of blistering, HIC and SOHIC. the use of special backfill, coating and _________.

A. Hydrogen A. Cathodic protection

B. Oxygen B. Resistivity
C. Cyanide C. Temperature
D. Caustic: C D. None of the above: A
322. __________ significantly increases the probability and severity 329. Soils having high moisture, high dissolved salt concentration
of blistering, HIC SOHIC damage. and high ____________ are the most corrosive.

A. Caustic A. Oxygen content

B. Cyanides B. Resistivity
C. Stress C. Acidity
D. Temperature: B D. All of the above: C
323. Since all fuels contain some amount of sulfur, sulfuric and 330. Soil to Air interface areas are usually more susceptible to
sulfurous acid __________ can occur if the metal temperature is corrosion than the rest of the structure because of _________
below this temperature. and ___________ availability.

A. Corrosion A. Moisture
B. Pitting B. Bacteria
C. Dew point corrosion C. Oxygen
D. All of the above: C D. B and C
324. Since cracking is usually surface connected, effective E. A and C: E
methods of inspection are: 331. Some units affected by HTHA are listed below. One of the
ones listed is usually not considered a target. Pick this unit.
a. WFMT and LT. a. Hydrocracker.
b. ET. and AE. b. Crude still.
c. VT. MT and PT. c. Catalytic Reformer.
d. AET, ET. and RT.: C d. Hydrotreater.: B
325. Smooth grooving of pipe walls is an indication that is the 332. Sour water corrosion in ___________ containing environments
causative agent. may be accompanied by carbonate SCC.
a. carbon monoxide
b. oxygen A. H²O
c. carbon dioxide B. H²S
d. hydrochloric or sulfuric acids: C C. CO²
326. SOHIC is driven by localized stresses so that ___________ is D. O²: C
somewhat effective in preventing SOHIC damage. 333. Spheroidization and graphitization are competing
mechanism that occur at overlapping temperature ranges.
A. PWHT Spheroidization tends to occur above _______ while
B. Preheat graphitization predominates below this temperature.
C. Temperature
D. None of the above: A A. 1000°F
B. 1025°F
C. 1050°F
D. 1100°F: B
334. SSC generally occurs below about _______. 341. Stainless steels with sigma can normally withstand normal
operating stresses but upon cooling to temperatures below
A. 150°F ______ may show a complete lack of fracture toughness as
B. 180°F measured by a Charpy impact test.
C. 210°F
D. 240°F: B A. 800°F
335. SSC generally occurs below about _________. B. 600°F
C. 500°F
A. 225°F D. 400°F: C
B. 200°F 342. Start-up and shutdown of equipment increase the
C. 180°F susceptibility of thermal fatigue. There is no limit on
D. 150°F: C temperature swings; however, as a practical rule, cracking
336. SSC is a form of hydrogen stress cracking resulting from may be suspected if the temperature swing exceeds about
the absorption of atomic hydrogen that is produced by the _______.
________ corrosion process in the metal surface.
A. 150°F
A. HCl B. 200°F
B. HF C. 250°F
C. Sulfide D. 300°F: B
D. Wet H²S: C 343. A Steam actuated soot blower has condensate in the first
337. SSC is a form of hydrogen stress cracking resulting from steam exiting the soot blower. What type of damage can be
the absorption of _________ that is produced by the sulfide expected to be found when the furnace is brought down for
corrosion process on the metal surface. maintenance and inspection?

A. Sulfur dioxide A. Thermal fatigue

B. Hydrogen sulfide B. Steam blanketing
C. Atomic hydrogen C. Creep
D. Hydrogen chloride: C D. Stress rupture: A
338. SSC is a form of _________ stress corrosion cracking. 344. Steam blanketing is when the heat flow balance is
disturbed; individual bubbles join to form a steam blanket, a
A. Hydrogen condition known as Departure from Nucleate Boiling (DNB).
B. Caustic Once a steam blanket forms, tube rupture can occur
C. Polythionic rapidly, as a result of __________.
D. Alkaline: A
A. Thermal fatigue
339. Stainless steel cyclones, piping ductwork and valves in high
B. Short term overheating
temperature FCC regeneration service are susceptible
C. Brittle fracture
areas for ____________.
D. Stress: B
A. Brittle fracture 345. Steel cleanliness and ________ have a significant influence on
B. Sigma phase toughness and resistance to brittle fracture.
C. Cavitation
D. Corrosion fatigue: B A. Composition
B. Alloy
340. Stainless steels have higher coefficients of thermal
C. Grain Size
expansion than carbon steel or low alloy steel or nickel
D. None of the above: C
based alloys and are more likely to see ________.
346. Steel hardness, ________ and stress are critical factors in
A. Higher temperatures causing hydrogen stress cracking.
B. Higher stresses
C. Higher pressure A. Temperature
D. None of the above: B B. Alloy composition
C. Strength
D. None of the above: C
347. Stress corrosion cracking usually occurs at metal 354. Sulfidation is primarily caused by _________ and other
temperatures above about: reactive sulfur species as a result of the thermal
a. 200 F. decomposition of sulfur compounds at high temperatures.
b. 160 F.
c. 140 F. A. Sulfur dioxide
d. 100 F.: C B. H²S
348. Stresses acting on the weldment are significantly __________ C. Sulfur trioxide
when austenitic stainless steel filler metal is used. A nickel D. Sulfates: B
based filler has a coefficient of thermal expansion closer to 355. Sulfidation is primary caused by:
carbon steel resulting in a significantly lower stress at
elevated temperatures. A. Impacting particles
B. Sulfur compounds decomposing at higher temperatures
A. Lower C. Sulfur compounds being created in the FCCU (cat
B. Higher cracking unit )
C. Altered D. Elemental sulfur collecting in stagnate areas, e.g. dead
D. None of the above: B legs.
349. Stress levels and ________ are the critical factors causing E. Operators failing to adequately control the pH of sulfur
carbonate stress corrosion cracking. streams.: B
356. Sulfidation of iron-based alloys usually begins at about:
A. Temperature
B. Velocity A. 150°F
C. Water chemistry B. 250°F
D. None of the above: C C. 500°F
350. Stress relief and stabilization heat treatment of 300 Series D. 1100°F: C
SS for maximizing chloride SCC and PASCC resistance can 357. Sulfidation of iron-based alloys usually begins at metal
cause __________ problems, especially in thicker sections. temperature above __________.

A. Thermal fatigue A. 500°F

B. Reheat cracking B. 600°F
C. Hydrogen C. 800°F
D. HIC: B D. 1000°F: A
351. Stress ruptures are characterized by _________ failures and 358. Sulfidation of iron-based alloys usually begins at metal
are usually accompanied by thinning at the fracture surface. temperatures above
a. 800°F
A. Rapid b. 700°F
B. Fish-mouth c. 600°F
C. Tensile d. 500°F: D
D. None of the above: B 359. Sulfidation usually creates:
352. The sudden rapid fracture under stress (residual or applied)
where the material exhibits little or no evidence of ductility A. Uniform corrosion
or plastic deformation is called __________. B. Isolated pitting
C. Intergranular cracking
A. 885°F D. Transgranular cracking
B. Temper embrittlement E. Hard and brittle zones
C. Stress corrosion cracking F. Inspection mightmares: A
D. Brittle fracture: D 360. Sulfide stress cracking (SSC) is defined as cracking of metal
353. Sufidation is also known as ________. under the combined action of tensile stress and corrosion
in the presence of ___________ and ___________.
A. Sulfur corrosion
B. Sulfate corrosion A. Sulfur, Oxide
C. Sulfidic corrosion B. Hydrogen, water
D. None of the above: C C. H²S, Oxygen
D. Water, H²S: D
361. Sulfur and chloride species in fuel will form sulfur dioxide, 367. Susceptibility to sulfidation is determined by the _______ of
sulfur trioxide and hydrogen chloride within the combustion the material.
products. At low enough temperatures, these gases and the
water Vapor in the flue gas will condense to form ___________ A. Corrosion resistance
acid. B. Tensile strength
C. Chemical composition
A. Hydrochloric D. Yield Strength: C
B. Hyrdofluoric 368. Susceptibility to temper embrittlement is largely
C. Sulfuric determined by the presence of the alloying elements
D. Both A and C: D manganese and _______.
362. Sulfur compounds react with carbon steel in high
temperature environments. This reaction causes corrosion. A. Chromium
The presence of____________ accelerates the corrosion. B. Moly
C. Silicon
a. water D. None of the above: C
b. carbon dioxide 369. Temperature, ___________ and stress are critical factors of
c. oxygen stress rupture. This is usually found in furnaces with cooking
d. hydrogen: D tendencies and fired heater tubes.
363. Sulfuric acid promotes general and localized corrosion of
carbon steel. Carbon steel heat affected zones may A. Pressure
experience severe corrosion. Acid concentration, B. Ductility
temperature, alloy content and _______ are critical factors C. Time
affecting sulfuric acid corrosion. D. Tensile strength: C
370. Temper embrittlement ____________ be prevented if the
A. Pressure material contains critical levels of embrittling impurity
B. Stress elements and is exposed in the embrittlement range.
C. Velocity
D. Ductility: C A. Can
364. Surface initiated cracks caused by environmental cracking B. Cannot
of 300 Series SS and some nickel based alloys under C. Will
combined action of tensile stress, temperature and aqueous D. None of the above: B
chloride environmental is called _________. The presence of 371. Temper embrittlement can be identified by a(n) ________ shift
dissolved oxygen _________ the propensity for cracking. in the ductile-to-brittle transition temperature measured in
a Charpy impact test.
A. CI SCC, increases
B. Stress cracking, increases A. Upward
C. CI SCC, Decreases B. Downward
D. Stress cracking, Decreases: A C. Abrupt
365. Susceptibility of an alloy to sulfidation is determined by its D. None of the above: A
ability to form protective _____________. 372. Temper embrittlement is a metallurgical change that is not
readily apparent and can be confirmed through _________.
A. Oxide scales
B. Sulfide scales A. Metallographic examination
C. Carbide scales B. Impact testing
D. None of the above: B C. Metallography
366. Susceptibility to hydrogen stress cracking __________ with D. None of the above: B
_________ hardness. 373. __________ testing is the best method to determine the
susceptibility of a material to hydrogen stress cracking.
A. Increases, increasing
B. Decreases, increasing A. Hardness
C. Decreases, Decreasing B. Acoustic
D. Both A and C: D C. SWUT
D. AUT: A
374. There is currently no known metal alloy that is immune to 381. Thermal fatigue is caused by:
_________ under all conditions.
A. Cyclic stresses that come from temperature variations
A. Carburization B. Long term operation at elevated temperatures
B. Metal dusting C. Excessive thermal growth
C. Decarburization D. Hours of physical activity during a hot summer day: A
D. None of the above: B 382. Three factors when critically combined tend to cause
375. Thermal fatigue becomes of concern if the temperature brittle fracture. Which of the four factors
swings exceed: listed below does not belong?
a. The material's fracture toughness (resistant to crack like
A. 50°F flaws) is low.
B. 100°F b. The size, shape and stress concentration of a flaw tends
C. 200°F to lead to failure.
D. 400°F: C c. The temperature is high enough to induce failure.
376. Thermal fatigue cracks propagate ____________ to the stress d. The amount of residual and applied stresses on the flaw
and are usually dagger shaped, transgranular and oxide- is enough to cause fracture.: C
filled. 383. Three of the steels listed below are susceptible to brittle
fracture. Pick the one that is not.
A. Axial
B. Diagonal a. Carbon steel.
C. Transverse b. 300 series of stainless steels.
D. Angular: C c. Low alloy steel.
377. Thermal fatigue cracks usually: d. 400 series of stainless steels: B
384. Three types of equipment with mechanical loading that are
A. initiate on the surface of the component affected by mechanical fatigue cracking are listed below.
B. Initiate in the subsurface of the component One of the four items listed below is not correct. Pick the
C. Grow very rapidly (at the speed of sound in the material) incorrect item.
D. Are very tight and narrow: A
378. Thermal fatigue cracks usually initiate on the _______ of the a. Rotating shafts on centrifugal pumps that have stress
component. They are generally wide and filled with oxides concentrations due to key ways.
due to the elevated temperatures. b. Small diameter piping that vibrates because of adjacent
equipment.
A. Surface c. Large, heavy, cast steel compressor cases.
B. ID d. High pressure drop control valves or steam reducing
C. Welds stations that have serious vibration problems: C
D. None of the above: A 385. Time to failure by thermal fatigue is primarily affected by:
379. Thermal fatigue cracks usually propagate ________ to the
stress and they are usually dagger-shaped. A. Magnitude of stress and operating temperature
B. Magnitude of stress and number of cycles
A. Parallel C. Carbon content in material and operating temperature
B. Diagonal D. Carbon content in material and number of cycles.: B
C. Transverse 386. Titanium Hydriding damage occurs primarily in sour water
D. Across: C strippers and amine units in the overhead condensers, heat
380. Thermal fatigue damage is in the form of cracking that may exchanger tubes and other titanium equipment operating
occur anywhere in a metallic component where relative above ________.
movement is constrained, particularly under repeated
________. A. 300°F
B. 270°F
A. Cyclic stresses C. 210°F
B. Thermal cycling D. 165°F: D
C. Pressure variations
D. All of the above: B
387. Titanium should not be used in known hydriding services 394. __________ usually occurs when a colder liquid contact a
such as ______ or _____. warmer metal surface.

A. Caustic, amine A. Stress cracking

B. Amine, sour water B. Thermal fatigue
C. Sour water, Alkylation C. Thermal shock
D. All of the above: B D. Stress shock: C
388. To prevent carburization, select alloys with strong surface 395. A vacuum tower operating at 740°F is being entered to
oxide or sulfide film former such as _________. inspect. Several sets of Type 410 SS trays are bent at
various angles. The trays are removed in order to straighten
A. Silicon them. When an attempt is made to straighten them cracks
B. Molybdenum form at the bends. What type of damage mechanism would
C. Aluminum cause the cracks to form?
D. Both A and C: D
389. To prevent hydrogen embrittlement, use lower strength A. Hydrogen embrittlement
steels and __________ to temper the microstructure, improve B. Sulfide stress corrosion cracking
ductility and reduce residual stress. C. 885°F embrittlement
D. High temperature corrosion: C
A. Alloys 396. Vessels constructed after December, 1987 are subject to
B. Preheat the requirements of _________ of ASME Section VIII, Division
C. PWHT 1.
D. All of the above: C
390. Type 304L SS is satisfactory for phosphoric acid A. UW-26
concentration of 100% up to about ___________. Type 316L is B. UG-31
required from there to 225°F. C. UB-54
D. UCS-66: D
A. 140°F 397. Vibration-induced fatigue can be eliminated or reduced
B. 150°F through _________ and the use of supports and vibration
C. 100°F dampening equipment. Material upgrades are not usually a
D. 120°F: D solution.
391. Typical HF Alkylation units operate with 1% to 3% water in
the acid, equivalent to an HF-in-water concentration of A. Hangers
97% to 99% and the temperatures are generally below B. Dummy legs
__________. C. Design
D. None of the above: C
A. 300°F 398. Ways to prevent thermal fatigue include stress
B. 250°F concentrators by making _________________ transitions at places
C. 200°F where the wall thickness changes.: smooth
D. 150°F: D 399. Weld heat affected zone graphitization is most frequently
392. Units where graphitization may be suspected are the FCCU found in the heat affected zone adjacent to welds in
and the _______ unit. narrow band, corresponding to the low temperature edge
of the heat affected zone, in multi-pass welded butt joints,
A. Hydrotreater these zones overlap each other covering the entire cross
B. Coker section. Because of its appearance, this type of
C. Alky graphitization is called ____________.
D. None of the above: B
393. __________ usually occurs when a colder liquid contact a A. Half-moon
warmer metal surface. B. Eyebrow
C. Radii
A. Brittle fracture D. None of the above: B
B. Thermal fatigue
C. Thermal shock
D. Stress rupture: C
400. Welds joining dissimilar materials (ferritic and austenetic) 408. What is the chemical symbol for ethane or ethylene?
may suffer ___________ related damage at high temperature
due to thermal expansion stresses. A. C²
B. C3
A. Stress C. C4
B. Creep D. CH4: A
C. Fatigue 409. What is the chemical symbol for propane or propylene?
D. Thermal stress: B
401. Wet H²S services or ___________ acid services are process A. C²
where hydrogen diffuses into the steel and hydrogen B. C3
embrittlement (HE) is an issue. C. C4
D. CH4: B
A. HF 410. What is the typical erosion-corrosion rate in mpy of Monel
B. Sulfuric immersed in a seawater flume with the seawater traveling
C. Caustic over it at 4 fps?
D. HCL: A
402. What alloying element determines the resistance of an a. 0.2 mpy
alloy to sulfidation? b. <0.2mpy
c. 1 mpy
a. Nickel. d. 0.3 mpy: B
b. Chrome. 411. What kind of steel is not susceptible to SCC?
c. Low carbon.
d. Columbium.: B a. AISI Type 347 SS.
403. What determines the likelihood and severity of corrosion b. AISI Type 316 SS.
for flue gas dew point corrosion? c. Carbon steel.
a. concentration of sulfur and chlorides in the fuel. d. Duplex SS: C
b. an excess of vanadium in the fuel. 412. What materials are affected most by atmospheric
c. condensation of hydrofluoric acid. corrosion?
d. none of the above.: A
404. What determines the susceptibility of an alloy to a. Nickel200, Inconel, and Incoloy.
sulfidation? b. Monel, Titanium, Duranickelalloy 301.
c. 300series stainless steels, and cast iron.
a. Its ability to form protective sulfide scales. d. Carbon steel, low alloy steels, and copper alloyed
b. The amount of nickel present. aluminum.: D
c. The ability to resist erosion. 413. What materials are usually affected by CUI?
d. The capability to avoid graphitic decomposition.: A
405. What is not a proven method for the detection of HTHA a. Cast iron, Nickel 2OO, and Aluminum.
damage? b. Titanium, Duranickel alloy 301, and Copper nickel.
a. VT. c. Monel, incoloy, and inconel.
b. AET. d. Carbon steel, low alloy steels, 300 series and duplex
c. WFMT. stainless steels.: D
d. RT: B 414. What method is most used to assure boiler feed water
406. What is the atmospheric corrosionrate if carbon steel is corrosion is not occurring?
exposed in a dry rural environment?
a. <4 mpy A. Spot UT readings at turbulent areas
b. <3 mpy B. Profile RT at turbulent areas
c. <2 mpy C. Profile RT and stagnant
d. <1 mpy: D D. Laboratory analysis of boiler feedwater: D
407. What is the chemical symbol for butane of butylenes? 415. What percent of chlorides is safe for exposure to 300 series
stainless steel?
A. C²
B. C3 a.15%
C. C4 b.10%
D. CH4: C c.5%
d.O%: D
416. What standard refers to Fitness-For-Service evaluations? 424. What type of on stream inspection method can detect the
loss of refractory on an operating unit?
A. RP 581
B. RP 579 a. Visual inspection.
C. RP 588 b. Infrared scan.
D.RP 568: B c. Ultrasonic scan.
417. What standard refers to Risk-Based-Inspection? d. Eddy current scan.: B
425. What type of unit suffers severe erosion-corrosion due to
A. RP 581 exposure to naphthenic acids in
B. RP 579 some crude oil?
C. RP 588
D. RP 568: A a. Catalytic Reformer Reactor piping.
418. What structure is 304 stainless steel? b. FCCU Fractionator overhead lines.
c. Hydroprocessing reactor effluent piping.
A. Martensitic d. Crude and Vacuum unit piping and vessels.: D
B. Austenitic 426. What usually causes corrosion in boiler feedwater and
C. Duplex condensate return systems?
D. Ferritic: B
419. What structure is 409 stainless steel? a. Corrosion pitting is the result of dezincification of the
tubes.
A. Martensitic b. Corrosion is the result of dissolved heavy water (020) and
B. Austenitic carbon monoxide (CO).
C. Duplex c. Corrosion is the result of HCI and H2SO4in the system.
D. Ferritic: D d. Corrosion is the result of dissolved gases, oxygen and
carbon dioxide.: D
420. What structure is 410 stainless steel?
427. When carbon is absorbed into a material at elevated
A. Martensitic temperatures while in contact with a carbonaceous
B. Austenitic substance it is called carburization. Temperatures usually
C. Duplex have to be above __________ for this to occur.
D. Ferritic: A
A. 1000°F
421. What test is used to determine a materials's toughness?
B. 1100°F
C. 1200°F
A. Charpy impact test
D. 1400°F: B
B. Guided Bend test
C. Tension Test 428. When caustic stress corrosion cracking is a concern, steam
D. Physical fitness test: A out of ___________ carbon steel piping and equipment should
be avoided.
422. What treatment is used to prevent boiler feed water
corrosion?
A. PWHT
B. Non-PWHT
A. Oxide scavengers are added to process
C. Ferritic
B. Oxygen scavengers are added to process
D. Hardened: B
C. Sulfide scavengers are added to process
D. Sulfur scavengers are added to process: B 429. When connected to a more anodic material, titanium may
suffer severe __________.
423. What type damage is caused by thermal fatigue?

A. Corrosion
a. Damage is in the form of severe oxidation and scaling.
B. Hydriding
b. Damage is in the form of cracking anywhere a movement
C. Stress
or expansion is constrained.
D. Notch toughness: B
c. Damage is in the form of tensile separation of high
stressed parts of equipment. 430. Where is PASCC normally located?
d. Damage is in the form of bending of parts that are highly
stressed.: B A. Adjacent to welds
B. On impellers
C. At stress risers
D. At flanges: A
431. Which API RP recommends programs to monitor small-bore 439. Which of the following are susceptible to thermal fatigue?
piping, flange faces, blistering and HIC/SOHIC if HF alky
units? A. SA-516-70
B. SA-182 Gr B
A. 574 C. SA-53 Gr B
B. 751 D. All of the above: D
C. 571 440. Which of the following can be affected by 885°F
D. 980: B Embrittlement?
432. Which if the following materials are subject to mechanical
fatigue? A. 410 SS
B. 430 SS
A. Carbon steels C. 308 SS
B. Stainless steels D. Alloy 2205
C. Low alloy steels E. A,B and D: E
D. All of the above: D 441. Which of the following does not increase the likelihood of
433. Which material below is not susceptible to caustic atmospheric corrosion?
corrosion?
A. Bird poop
A. Carbon steel B. Increasing annual rainfalls
B. 400 Series SS C. Locations where moisture
C. 300 Series SS D. Increasing operating pressures
D. Low alloy steel: B E. Increasing amounts of airborne contaminates: D
434. Which material does not have endurance limit? 442. Which of the following is not a critical factor that
contributes to a brittle fracture?
A. Non-normalized carbon steel
B. Normalized carbon steel A. The material's fracture toughness
C. Stainless Steel B. Maximum operating temperature
D. Titanium: C C. Stress concentration at at flaw
435. Which of following materials are not susceptible to D. Magnitude of the residual stresses: B
hydrogen stress cracking? 443. Which of the following is not a major factor associated with
boiler water condensate corrosion?
A. Carbon steel
B. Low alloy steel A. Operating pressure
C. Stainless steel B. Oxygen
D. None of the above: C C. Carbon dioxide content
436. Which of the following alkanolamine systems is the least D. Process pH
aggressive in causing amine corrosion? E. Temperature: A
444. Which of the following is not a major factor associated with
A. Monoethanolamine (MEA) corrosion by sulfidation?
B. Diglycolamine (DGA)
C. Diethanolamine (DEA) A. Alloy composition
D. Methyldiethanolamine (MDEA): D B. Operating pressure
437. Which of the following alkanolamine systems is the most C. Operating temperature
aggressive in causing amine corrosion? D. Sulfur content: B
445. Which of the following is not a method used to prevent
A. Monoethanolamine (MEA) brittle fracture?
B. Diglycolamine (DGA)
C. Diethanolamine (DEA) A. Thorough inspections
D. Methydiethanolamine (MDEA): A B. Strict controls on selecting construction materials
438. Which of the following are affected by sulfidation? C. Post weld heat treatment
D. Controlling minimum operating temperatures: A
A. Carbon steel
B. 300 Series SS
C. 400 Series SS
D. All of the above: D
446. Which of the following is not a primary factor contributing 453. Which of the following materials are susceptible to
to erosion-corrosion? polythionic acid SCC?

A. Impact angle (angle that impacting particles strike metal) A. 300 Series SS
B. Tensile strength of the metal B. Alloy 600
C. Velocity of impacting particles C. Alloy 800
D. Corrosiveness of the environment.: B D. All of the above: D
447. Which of the following is not a prime candidate for thermal 454. Which of the following materials are the least susceptible
fatigue? to caustic embrittlement?

A. Coke drums A. Carbon steel

B. Steam actuated soot blowers B. Stainless steel
C. Mix points of hot and cold streams C. 9Cr-0.5Mo
D. 600 psig steam piping D. Nickel base alloys: D
E. Welds joining materials having different coefficients of 455. Which of the following materials is affected by high
expansion: D temperature corrosion?
448. Which of the following is not primary factor contributing to
erosion? A. Carbon Steel
B. 300 Series SS
A. Impact angle (angle that impacting particles strike metal) C. 400 Series SS
B. Size if impacting particles D. All of the above: D
C. Velocity of impacting particles 456. Which of the following materials is least affected by
D. Density of impacting particles atmospheric corrosion?
E. Corrosiveness of the environment.: E
449. Which of the following is not primary initiating point for A. Carbon steel
thermal fatigue? B. Chromes
C. Stainless steels
A. Notches D. Copper alloyed with alumimum: C
B. Rounded pits 457. Which of the following materials is least effected by brittle
C. Nozzle-to-shell welds fracture?
D. Weld toes: B
450. Which of the following materials are affected by A. Carbon Steel
mechanical fatigue cracking? B. Chromes
C. 300 Series stainless steels
A. Only carbon steel D. 400 Series stainless steel
B. Only carbon steel and chromes E. All Stainless steels: C
C. Only carbon steel and high nickel alloys 458. Which of the following materials is not susceptible to CI
D. All materials: B SCC?
451. Which of the following materials are generally not suitable
for HF service? A. 400 Series SS
B. Duplex SS
A. 300 Series SS C. Nickel based alloys
B. Carbon Steel D. All of the above: A
C. 400 Series SS 459. Which of the following materials is not susceptible to high
D. Both A and C: D temperature hydrogen attack?
452. Which of the following materials are susceptible to
nitriding? A. 300 Series SS
B. 5Cr-1Mo
A. Carbon Steel C. 9Cr-1Mo
B. 300 Series SS D. All of the above: D
C. 400 Series SS
D. All of the above: D
460. Which of the following materials is not susceptible to SCC? 468. Which of these materials are not susceptible to
Spheroidization?
A. Carbon steel
B. 300 Series SS A. Carbon Steel
C. Low alloy steel B. 9Cr-1Mo
D. Both A and C: D C. 316 SS
461. Which of the following materials is susceptible to D. Both A and B: C
carburization? 469. Which of these materials are susceptible to brittle fracture?

A. Low alloy steels A. Carbon steels

B. 300 Series SS B. Low alloy steels
C. 400 Series SS C. 400 Series SS
D. All of the above: D D. All of the above: D
462. Which of the following materials is susceptible to CO² 470. Which of these materials are susceptible to creep damage?
corrosion?
A. Carbon Steel
A. Carbon steel B. Stainless Steel
B. Stainless steel C. Low alloy steel
C. Duplex stainless steel D. All of the above: D
D. Both B and C: A 471. Which of these materials exhibit an endurance limit below
463. Which of the following materials is susceptible to sigma which fatigue cracking will not occur?
phase embrittlement?
A. Carbon Steel
A. Carbon Steel B. 300 Series SS
B. Low alloy C. 400 Series SS
C. 300 Series SS D. None of the above: A
D. Both A and B: C 472. Which of these materials is not susceptible to amine
464. Which of the following metals is the most anodic? cracking?

A. Zinc A. Carbon steel

B. Carbon Steel B. 300 Series SS
C. Nickel C. 400 Series SS
D. Monel: A D. Both B and C: D
465. Which of the methods are effective for finding thermal 473. Which of these materials is susceptible to 885°F
fatigue cracks? embrittlement?

A. MT A. 400 Series SS
B. PT B. Duplex SS
C. VT C. 5Cr-1Mo
D. All of the above: D D. Both A and B: D
466. Which of these cast irons are not susceptible to graphitic 474. With 885°F embrittlement, increasing amounts of _______
corrosion? increase susceptibility to damage when operating in the
high temperature range of concern.
A. Gray cast iron
B. Black cast iron A. Chromium
C. White cast iron B. Hardness
D. None of the above: C C. Ferrite
467. Which of these materials are not susceptible to PASCC? D. Hydrogen: C
475. With ammonia stress corrosion cracking weld hardness
A. Carbon steel should not exceed _______ BHN.
B. 300 Series SS
C. 400 Series SS A. 237
D. Both A and C: D B. 225
C. 235
D. 218: B
476. With chloride stress corrosion cracking, ___________ 483. With HF acid corrosion, oxygen contamination __________ the
temperatures ____________ the susceptibility for cracking. corrosion rate of carbon steel and promotes accelerated
corrosion and SCC of Alloy 400.
A. Decreasing, Increases
B. Increasing, Increases A. Increases
C. Increasing, Decreases B. Decreases
D. Decreasing, Eliminates: B C. Maintains
477. With CI SCC, _________ levels of chloride _______ the likelihood D. Elimanates: A
of cracking. 484. With high temperature hydrogen attack, ________ using a
combination of velocity ratio and backscatter have been
A. Decreasing, Increases the most successful in finding cracking.
B. Increasing, Decreases
C. Increasing, Increases A. MT
D. Increasing, Eliminates: C B. UT
478. With CO² corrosion, increasing temperature ________ C. RT
corrosion rates up to the point where CO² is vaporized. D. EC: B
485. With high temperature sulfide corrosion (sulfidization),
A. Decrease noticeable increases may be found downstream of ________
B. Increase injection points.
C. Eliminate
D. None of the above: B A. Hydrogen
479. With cooling water corrosion, _________ oxygen content B. Caustic
tends to _______ carbon steel corrosion rates. C. Ammonia
D. Water: A
A. Increasing, increase 486. With hydrofluoric acid corrosion, corrosion rates increase
B. Decreasing, decrease with ________ temperatures and ________ HF concentrations.
C. Decreasing, increase
D. Increasing, decrease: A A. Increasing, decreasing
480. With creep, increased stress due to loss in thickness from B. Decreasing, increasing
corrosion will _________ time to failure. C. Increasing, increasing
D. Decreasing, decreasing: A
A. Increase 487. With short term overheating, time to failure will __________ as
B. Reduce internal pressures or loading decrease.
C. Not affect
D. None of the above: B A. Increase
481. With CUI, corrosion rates ________ with increasing metal B. Decrease
temperatures up to the point where the water evaporates C. Remain the same
quickly. D. None of the above: A
488. With sour water corrosion, at a given pressure, the H²S
A. Decrease concentration in the sour water _________ as temperatures
B. Increase __________.
C. Stay the same
D. None of the above: B A. Increases, increases
482. With decarburization, the decarburized layer will be free of B. Decreases, decreases
carbide phases. Carbon steel will be _________. C. Increases, decreases
D. Decreases, increases: D
A. Annealed 489. With sour water corrosion, corrosion increase with __________
B. Quenched NH4HS concentration and _________ velocity.
C. Pure Iron
D. None of the above: C A. Increasing, decreasing
B. Increasing, increasing
C. Decreasing, Decreasing
D. Decreasing, increasing: B
490. With sour water corrosion, streams with a pH below ________ 497. With thermal fatigue, time to failure is a function of the
indicate the presence of a strong acid. magnitude of stress and the number of cycles and
decreases with _________ stress and _________ cycles.
A. 7.0
B. 5.5 A. Increasing, decreasing
C. 6.0 B. Increasing, increasing
D. 4.5: D C. Decreasing, decreasing
491. With steam blanketing, failure occurs as a result of _______ in D. Decreasing, Increasing: B
the tube from the internal steam pressure at the elevated 498. With very few exceptions, cooling water should always be
temperature. on the ______ side to minimize stagnant areas.

A. Stress risers A. Tube

B. Velocity B. Shell
C. Hoop stress C. Inlet
D. Tensile strength: C D. Outlet: A
492. With sulfidation, the presence of oxygen _________ corrosion.

A. Increases
B. Decreases
C. Has not effect on
D. Stops: A
493. With sulfuric acid corrosion, alloys such as Alloy 20 resist
dilute corrosion and form a protective _________ film on the
surface.

A. Sulfide
B. Chloride
C. Iron sulfate
D. Iron oxide: C
494. With sulfuric acid corrosion, carbon steel corrosion rates
increases significantly if the flow velocity exceeds about
___________ fps or at acid concentrations below ________.

A. 6-9, 80%
B. 5-7, 75%
C. 2-3, 65%
D. 4-6, 85%: C
495. With sulfuric acid corrosion, mix points with _______ cause
heat to be released and high corrosion rates can occur
where the acid becomes diluted.

A. Water
B. Hydrogen
C. H²S
D. Caustic: A
496. With sulfuric acid corrosion, the presence of oxidizers can
_______ the corrosion rate.

A. Increase
B. Decrease
C. Stabilize
D. Eliminate: A