API-571 Mockup Test-04-Questions
Mockup Questions Test-4
1. Most inspections are performed visually and followed by …………………on several-year
intervals.
A. PT or WFMT
B. MT or UT
C. SWUT
D. A & C
2. Tubes should be examined for evidence of diametric growth (creep) with
A. strap or go/no go gauge,
B. MPI
C. in place replicas or tube samples.
D. A & C
3. The vessels is made of 2.25Cr-1Mo steels which is used for high temperature
applications, If this is susceptible for temper embrittlement which area in the vessel
should be evaluated
A. Base metal area
B. Welds
C. Nozzle intersections
D. All of the above
4. Cracking that may occur anywhere in a metallic component where relative movement or
differential expansion is constrained, particularly under repeated thermal cycling ths
damage mechanism is called as
A. Mechanical fatigue
B. Thermal fatigue
C. Corrosion Fatigue
D. All of the Above
5. As a practical rule, cracking may be suspected if the temperature swing exceeds about
A. 200°F (93oC)
B. 150 C
C. 50 C
D. None of the above
6. An application for cold Water on hot tube which results in thermal fatigue
A. Steam actuated soot blowers, if the first exiting the steam contains water
condensate
B. rigid attachments and a smaller temperature differential in super heater and
reheater tubes
C. water lancing or water cannon use on waterwall tubes
D. All of the above
7. -------------------is designed to accommodate relative movement may become frozen and
act as a rigid attachment when plugged with fly ash.
A. Restrained component
B. Slip Spacers
C. Tracers
D. None of the above
8. Thermal fatigue cracking has been a major problem in where Stresses are prompted by
variation in temperature
A. Coke drum shells
B. Coke drum skirts
C. Burners
D. All of above
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9. ________form of corrosion that can occur at the junction of dissimilar metals when they
are joined together in a suitable electrolyte, such as a moist or aqueous environment,
or soils containing moisture.
A. Atmospheric corrosion
B. Galvanic corrosion
C. Corrosion under insulation
D. Concentrated corrosion.
10. The conditions required for galvanic corrosion are except
A. Electrolyte, the fluid that can conduct current (moisture or water phase)
B. Two different materials (anode & cathode)
C. Temperature
D. Electrical connection existing between anode and cathode
E. None of the above.
11. In a galvanic couple more noble material is anode, which corrodes at a higher rate than it
would if it were not connected to the cathode.
A. True
B. False
12. The more noble material (anode) is protected by the sacrificial corrosion of the more
active material (cathode)
A. True
B. False
13. The order of material from active to noble materials for (Corroded end towards protected
end)
A. Steel, Nickel, Magnesium, Platinum
B. Platinum, Nickel, Steel & Magnesium
C. Magnesium, Nickel, Steel, & Platinum
D. Magnesium, Steel, Nickel & Platinum
14. In the series of Noble materials passive state of stainless steel & Ni alloys are towards
protected end
A. True
B. False
15. The areas where atmospheric corrosion is less likely
A. Marine environments
B. Moist tainted industrial environments
C. Wet and humid urban environments
D. Dry rural environments.
16. Atmospheric corrosion affects these materials except
A. Stainless steel & nickel alloys
B. Copper and aluminum alloys
C. Low alloy steels
D. Carbon steels
17. Materials which are highly resistant to Cl-SCC
A. Duplex SS
B. Nickel base SS
C. 300 series SS
D. All of the above
18. Cl-SCC usually occurs above a pH value of
A. 7.0
B. 9.0
C. 5.0
D. 2.0
19. Materials which are not susceptible to Cl-SCC
A. 300 series
B. CS, LAS & 400 series SS
C. Duplex SS
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D. All of the above
20. Bellows and instrument tubing, particularly those associated with hydrogen recycle
streams Contaminated with chlorides, can be affected by - Cl-SCC
21. Cracks which occurs on the 300 series piping externally under wet insulation were
predominantly due to
A. PTA-SCC
B. Cl-SCC
C. CUI
D. NAC
22. Appearance of cracks due to Cl-SCC
A. Craze cracks with branches
B. Transgranular
C. Intergranular of sensitized 300 series SS
D. Brittle fractured surface
E. All of the above
23. Methods to avoid / mitigate Cl-SCC
A. When hydrotesting, use low chloride content water and dry out thoroughly and
quickly.
B. Properly applied coatings under insulation.
C. Avoid designs that allow stagnant regions where chlorides can concentrate or
deposit.
D. high temperature stress relief of 300 Series SS after fabrication to reduce
residual stresses.
E. All of the above
24. Preferred methods to identify Cl-SCC
A. RT
B. Phase analysis EC
C. PT
D. b & c
25. A form of stress cracking in which cracks develop under the combined affects of cyclic
loading andcorrosion
A. Mechanical Fatigue
B. Thermal fatigue
C. Corrosion fatigue
D. None of the above
26. Cracking due to corrosion fatigue occur in environments that promote _________ or
localized corrosion under cyclic stresses due to thermal stresses, vibration or
differential expansion.
A. Blisters
B. Pitting
C. Cracks
D. Bulges
27. Contrary to pure mechanical fatigue there is _______ fatigue limit load in corrosion
fatigue failures
A. High
B. low
C. Equal
D. No
28. Equipment prone to corrosion-fatigue failures (subjected to cyclic stresses in corrosion
environment)
A. De-aerators,
B. Cycling boilers,
C. Rotating equipment
D. All of the above
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29. Galvanic couples between the impeller and pump shaft may result __________ on the
shaft
A. Grooves
B. Blisters
C. Pitting
D. Cracks
30. Cracks on the shafts in rotating equipment occurred due to corrosion fatigue failures
appearance would be mostly of
A. Intergranular with no branches
B. Intragranular with little branches
C. Both the above
D. No cracks will occur due to corrosion fatigue
31. The de-aeration vessels in paper, pulp, refinery industries in late 1980’s had major
failures due to mechanism of
A. Corrosion fatigue
B. Cl-SCC
C. Thermal fatigue
D. Mechanical fatigue
32. Due to differential thermal expansion in the cycling boilers which generally see several
cold starts, cracks will occur in the _____________ allows corrosion to continue
A. Oxidized scale
B. Pearlite scale
C. Magnetite scale
D. Sulfur scale
33. Type of failure occurs as a result of steam blanketing is
A. Circumferential stress failure
B. Hoop stress failure
C. Tensile stress failure
D. None of the above
34. the type of failure can occur in superheaters and reheaters during start-up when
condensate blocks steam flow is
A. Short term overheating
B. Thermal fatigue
C. Nucleate boiling
D. All of the above
35. To control the heat flux and fluid flow in boiler super heater tubes what preventive
measures to be taken
A. Proper Burner management and Proper Boiler Feed water treatment
B. Proper flame impingement and proper feed water flow
C. Proper fuel flow and proper feed water flow
D. None of the above
36. the appearance of damage due to high temperature failures are often show an
A. Open burst with the fracture edges drawn to a near knife-edge
B. open burst with blunt fracture edge
C. Bulging
D. None of the above
37. The temperatures where scaling potential increases
A. Fresh water process temperature goes above
B. Brackish water above 46 C
C. Fresh water & Brackish water above 60 C
D. Both a & b
38. In a cooling water service of titanium piping the process temperature are above about 82
C and titanium connected to more anodic material, then piping may suffer with
A. Hydriding
B. Cooling water corrosion
C. Galvanic corrosion
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D. Erosion –corrosion
39. Velocity which promote cooling water corrosion due to increase fouling
A. less than 1 m/s
B. less than 3 fpm
C. more than 1 m/s
D. more than 3 fpm
40. Copper/zinc alloys can suffer __________ in fresh, brackish and salt water systems. The
copper/zinc alloys can suffer _________if any ammonia or ammonium compounds
are present in the water or on the process side.
A. Cooling water corrosion, dezincification
B. Cooling water corrosion, stress corrosion cracking
C. Dezincification, cooling water corrosion
D. Dezincification, stress corrosion cracking
41. Erosion and erosion-corrosion are characterized by ------------- and often exhibit…………….
A. A localized loss of thickness, directional pattern
B. General, directional pattern
C. Crack, directional pattern
D. None of the above
42. Erosion-corrosion is best mitigated by
A. using more corrosion-resistant alloys and/or altering the process environment to
reduce corrosivity,
B. Improvements in design involve changes in shape, geometry and materials selection
(more corrosion-resistant alloys) and/or altering the process environment to reduce
corrosivity,
C. through increasing substrate hardness using harder alloys, hardfacing or surface-
hardening treatments.
D. None of the above
43. Higher …………….element containing alloys are used for improved resistance to naphthenic
acid corrosion.
A. Molybdenum
B. Titanium
C. Silicon
D. Manganese
44. The type of inspection and monitoring are used to detect refractory loss in onstream
A. IR scans
B. Profile Radiography
C. UT
D. All of the above
45. Amine inhibitor treatments may be required to __________ the condensate return piping
system of a steam generating unit.
A. Minimize oxygen
B. Minimize sulfur
C. Minimize CO2
D. Minimize Hydrogen
46. Material resistant to Carbon dioxide corrosion
A. C – 0.5 Mo
B. 2.25 Cr – 1 Mo
C. 9 Cr – 1 Mo
D. 12 Cr -1 Mo
47. Due to CO2 corrosion, CR of 1000mpy or more are observed in effluent streams of shift
converters in hydrogen plants when the stream drops below the dew point temperature of
A. 54 deg C
B. 87 deg C
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C. 138 deg C
D. 149 deg C
48. Inner surface of a piping and root of the welds was noticed with deep pitting & grooving
due to flow turbulence the most possible reason could be due to
A. Cooling water corrosion
B. CO2 corrosion
C. Pitting corrosion
D. Erosion corrosion
49. Anhydrous ammonia with _______ % water will cause stress corrosion cracking in
carbon steel
A. <2.0 %
B. <0.2 %
C. >2.0 %
D. >0.2%
50. On copper alloys, surface breaking cracks with bluish color corrosion products are
generally due to
A. High temperature corrosion
B. Sulfide stress carrion cracking
C. Ammonia stress corrosion cracking
D. Passivation
51. On exchanger tubes made up of copper alloys, due to NH3 SCC, cracking may show
single or highly branched on surface either transgranular or Intergranular, depends upon
environment and __________
A. pH
B. Diameter of tube
C. Thickness of tubes
D. Stress levels
52. 90-10 CuNi and 70-30 CuNi, 300 SS & Nickel base alloys are immune to
A. Chloride stress corrosion cracking
B. Sulfur stress carrions cracking
C. Caustic embrittlement
D. Ammonia stress corrosion cracking
53. On copper alloys NH3 SCC in steam service can sometimes be controlled by preventing
A. Feed water contaminants
B. Air ingression
C. Flame impingement
D. Oxidation.
54. Method(s) to prevent NH3 SCC in carbon steel
A. PWHT
B. Preheating
C. Adding small quantities of water (0.2%)
D. Both A & C
55. To prevent NH3 SCC in carbon steel welds, hardness should not exceed
A. 125 BHN
B. 225 BHN
C. 325 BHN
D. 275 BHN
56. Areas where copper alloy heat exchanger tubes highly susceptible for NH3 SCC are
A. U – Bend areas
B. At Baffle locations
C. Opposite to shell side inlet (Impingement areas)
D. Rolled areas
57. Applicable methods for detecting damage of cast irons due to graphitization, Hardness
tend to reduce due to dealloying / Graphitic corrosion.
A. Ultrasonic thickness
B. Ultrasonic Attenuation
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C. Gamma-Ray radiography
D. X-Ray
58. Acoustic technique to identify the damage mechanism of graphitic corrosion is also
known as _________
59. Graphitic corrosion in grey cast irons can be prevented by
A. Coatings / Linings
B. Upgrading metallurgy to Stainless steel
C. Use White cast iron (No free graphite available)
D. All of the above
60. Graphitic corrosion can occur in soft water, salt water, mine waters, dilute acids and in
underground piping as well as in boiler feedwater equipment. Typical examples
include feedwater piping, pumps (including pump impellers), valves, and
underground cast iron pipe. Fire water systems are particularly vulnerable.
61. Monitoring methods to monitor / inspect steel storage tanks or piping in anhydrous
ammonia environment
A. WFMT welds inside tanks
B. External UT shear wave
C. AET
D. All of the above
62. The form of cracking which may occur sudden and brittle in nature which results when
certain molten metals come in contact with specific alloys.
A. Fuel ash corrosion
B. Liquid metal embrittlement
C. Thermal fatigue
D. None of the above
63. Materials highly resistant to liquid metal embrittlement
A. Titanium alloys
B. Aluminum alloys
C. 300 SS & Nickel base alloys
D. CS & LAS
E. None of the above
64. Combinations of alloys with molten metals susceptible for Liquid metal embrittlement are
A. 300 series SS – Zn
B. Cu, Al alloys – Hg
C. Alloy 400 – Hg
D. High strength steel – Cd & Pb
E. All of the above
65. RT is highly sensitive to cracks occurred due to Hydrogen embrittlement
A. True
B. False
66. Hydrogen embrittlement occurs at locations of high residual or tri-axial stresses (notches,
restraint) such as weld HAZ’s. where PWHT is not applied
A. True
B. False
67. Wet H2S services or HF acid services in which atomic hydrogen diffuses into the steel.
(Cyanides,arsenic and FeS can act as hydrogen recombination poisons that diminish the
hydrogen gas Reaction and allows for greater charging rates.)
A. True
B. False
68. Bolts and springs made of high strength steel are very prone to Hydrogen
embrittlement. (Alloys that have a tensile strength above 150 ksi can absorb
hydrogen during electroplating and crack.)
A. True
B. False
69. Following material is not usefully resistant to HCL corrosion at any concentration or
temperature
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A. Copper-Nickel alloys
B. Carbon steels
C. 300 series SS and 400 series SS
D. None of the above
70. Damage in refineries is most often associated with dew point corrosion in which vapors
containing water and hydrogen chloride condense from the overhead stream of a
distillation, fractionation or stripping tower is
A. HF corrosion
B. HCL Corrosion
C. Napthenic acid corrosion
D. All the above
71. ………………is normally not corrosive in dry process streams, but becomes very
corrosive where water is available to form hydrochloric acid.
A. Hydrogen chloride
B. Hydrogen sulphide
C. Hydrogen
D. Chlorides ions
72. Following materials are affected by HCL corrosion
A. Copper-Nickel alloys
B. Carbon steels
C. Alloy 400 and C276
D. All common materials
73. -------------------- will solve most overhead condenser tube HCL corrosion problems.
A. Nickel
B. Titanium
C. Low alloy steel
D. All of the above
74. The common methods to dilute the HCL concentrations in overhead streams in crude
units are
A. Caustic injection and acid washing, neutralizing amines and filming amines
B. Caustic injection and water washing , neutralizing amines and filming amines
C. Caustic injection and desalting , neutralizing amines and filming amines
D. None of the above
75. in what material the damage is usually in the form of general thinning but may be highly
localized where a water phase is condensing.
A. Carbon steel
B. 300 series SS
C. Nickel based alloys
D. Titanium
76. Locally thinned areas due to HCL corrosion can be found what technique
A. automatic ultrasonic scanning methods or profile radiography.
B. UT thickness gauging
C. ECT
D. Real time radioscopy
77. NAC is primarily associated with hot wet hydrocarbon streams that contain free water
phase
A. True
B. False
78. If the crude contains sulfur with TAN________, NAC could be predominant
A. as high as 0.10
B. as low as 1.0
C. as low as 0.10
D. as high as 1.0
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79. In hot coker gas oil streams Napthenic acid corrosion is observed when the temperature
operating upto
A. 350 F
B. 750 F
C. 800 F
D. 425 F
80. Alloy which shown improved resistance to NAC is _____________ and ________
percentage is required depending on TAN of the whole crude units and its side cuts.
A. Ni, 20 to 30 %
B. Mo 2 to 2.5 %
C. Cr 18 to 24 %
D. Cu 1.8 to 3.0 %
81. For equipments / piping suffering with severe NAC, metallurgical up gradation to be
considered and suitable material could be
A. SS 310 L
B. SS 304 L
C. SS 317 L
D. SS 410
82. NAC can be reduced by blending crude to reduce the TAN and/or increase the
_______content.
A. Sodium
B. Sulfur
C. Phosphorus
D. Water
83. Primary inspection method to detect NAC
A. RT
B. UT
C. PT
D. Visual
84. Streams which are susceptible for NAC, monitor for _____content to assess corrosion in
the system
A. Fe & Ni
B. Fe & S
C. Sulfur
D. TAN
85. This is the proven method of preventing carbonate cracking
A. Application of post fabrication stress relieving of about 1150 0F
86. Following materials are not suitable for HF service
A. Carbon steel, copper-nickel alloys
B. Alloy 400, Alloy C276
C. Low alloy steels, 300 series SS and the 400 series SS
D. All of the above
87. Primary concern of HF acid corrosion is
A. Presence of water
B. Presence of Nitrogen
C. HF concentration
D. None of the above
88. HF acid corrosion increases with
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A. Increase in temperature and HF concentration
B. decrease in temperature and increase in HF concentration
C. Increase in temperature and decrease in HF concentration
D. Decrease in temperature and HF concentration
89. Where there have been cracking problems with Alloy 400 in HF service following material
can be used
A. Copper nickel alloys
B. FRP or GRP
C. Alloy C276
D. None of the above
90. Carbon steel up to this temperature limit can resist HF acid corrosion
A. 500F
B. 1500F
C. 2500F
D. 3500F
91. HF acid corrosion is in the form of
A. Localized or severe thinning of carbon steel
B. Alloy 400 shows uniform loss in thickness
C. Environmental cracking of carbon steel and Alloy 400 can occur in HF
92. Hydrogen stress corrosion cracking takes place when Carbon steel or Low alloy steels
exposed to
A. Aqueous HF acid
B. Aqueous HCL
C. Aqueous H2SO4
D. none of the above
93. Primary concern of phosphoric acid corrosion is
A. Increase in Water
B. Increase in phosphoric acid concentration
C. Decrease in water
D. None of the above
94. Sulfuric acid primarily affects
A. Carbon steel weld metal
B. Carbon steel base metal
C. Carbon steel weld heat affected zone
D. All of the above
95. In low flow or stagnant units of H2SO4 following damage mechanism may takes place
A. Wet H2S damage
B. Hydrogen grooving
C. Chloride stress corrosion cracking
D. All of the above
96. Carbon steel corrosion rates in H2SO4 increases significantly when velocity exceeds
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A. 1 to 2 mps
B. 2 to 3 mps
C. 1 to 2 fps
D. 2 to 3 fps
97. Carbon steel corrosion rates in H2SO4 increases significantly at concentrations
A. <45%
B. <55%
C. <65%
D. <75%
98. In H2SO4 service alloys such as Alloy 20, Alloy 904L and Alloy C-276 resist dilute acid
corrosion and form a protective iron sulfate film on the surface.
99. Naphthenic acid corrosion is a
A. Low temperature corrosion
B. High temperature corrosion
C. Very low temperature corrosion
D. Not related to temperature
100. Naphthenic acid corrosion normally takes place at temperatures
A. >150 deg F
B. >250deg F
C. >350 deg F
D. >450 deg F
101. PASCC mostly occurs
A. During shutting down
B. During start up
C. While in operation
D. None of these
102. PASCC mostly occurs
A. During shutting down
B. During start up
C. While in operation
D. None of these
103. Sensitization occurs in this temperature range
A. 750 to 1000 degF
104. Sensitization occurs in this temperature range
A. 750 to 1000 degF
105. PASCC can be monitored during operation by following technique
A. PT
B. ACFM
C. WFMT
D. Not present while operating
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