1.

If thermal shock damage may be present, which of the following should be

checked?
a) Bulging of Elbows
b) Hot / Cold Injection Points
c) Hardness of the furnace outlet piping
d) Surface exfoliation of furnace tubes

2. Brittle fracture occurs only at

a) High temps in areas of high stress concentration
b) Temps below freezing
c) Temps below the charpy impact transition temp
d) Temps above the charpy.

3. Which of the following is the most affective method of preventing or mitigating

galvanic corrosion
a) Placing an electric insulating material between the anodic material &
cathodic material.
b) Keep the anode / cathode coupling under water
c) Appling PWHT
d) Sensitizing at 1100F (593c)

4. Differential expansion in bimetallic welds can give rise to

a) Reheat cracks
b) Thermal fatigue
c) Dissimilar weld flaws
d) Galvanic cracking

5. Sulfidation of iron-based alloys usually begins at temps above?

a) 300F
b) 400F
c) 500F
d) 650F

6. Grooving in cooling water tubes could be the result of :

a) Electric resistance welds
b) Flow induced erosion
c) Microbiologically induced corrosion
d) Underdeposit corrosion

7. In brass alloys, dealloying corrosion most commonly removes:

a) Tin
b) Zinc
c) Nickel
d) Copper
8. The possibility of corrosion under insulation for 300 series SS is greatest :
a) Around damaged or leaking steam tracing
b) In an area insulated with older calcium silicate insulation
c) In an area with damaged vapor barriers or weather proofing
d) In the first few feet of a horizontal pipe run adjacent to the bottom of a
vertical run.

9. Caustic corrosion is most often associated with:

a) Boilers & steam generating equipment
b) Caustic treaters
c) Caustic injections in crude units
d) Caustic storage tanks (non-PWHT)

10. CUI Prevention is best achieved by:

a) Routine RB corrosion under insulation Inspection
b) Removing insulation where it is not mandatory for process reasons
c) Maintaining coating/insulation barriers
d) Avoiding steam tracing by using electric tracing.

11. Metal loss caused by collapsing vapors, air or gas bubbles entrained in a liquid
medium is called?
a) Vibration fatigue
b) Erosion
c) Erosion-corrosion
d) Cavitation

12. For a refractory lined pipe that is out of service, gas free and large enough to
enter. the most effective inspection method is?
a) RT
b) VT
c) UT
d) Thermal imaging.

13. In a fired heater burning fuel oil with impurities, corrosion would be most likely
to occur first in the?
a) Shock tubes
b) Convection tubes
c) Tube supports
d) Radiant tubes

14. Erosion & Erosion-corrosion are characterized by:

a) Generalized thinning in low spots of piping systems
b) Generalized thinning in areas perpendicular to the flow of the impacting
medium.
c) Localized loss of thickness in the form of pits or grooves.
d) Localized loss of thickness in the form of sharp-edged pitting.
15. Which of the following statements about reheat cracking is most accurate?
a) It is independent of stress level
b) It occurs primarily during multiple PWHT.
c) It occurs only in direct-fired heaters and boiler.
d) It occurs either during PWHT or in-service at high temperature.

16. The best method for finding damage from sigma phase embrittlement is?
a) RT
b) Angle beam UT
c) VT
d) Metallographic exam

17. Chloride SCC of 300 series SS initially becomes a concern at a metal temperature
above?
a) 100F
b) 140F
c) 180F
d) 212F

18. Brittle fracture is most likely to result from which of the following?
a) Residual or applied stress, susceptible material and critical flaws
b) Material with less than " thickness and some corrosion
c) Surface decarburization & fine grain structure
d) High strength material with low ductility

19. Sour water corrosion is best found through?

a) Acoustic emission test
b) UT & Profile RT
c) Thermal Image testing
d) Angle beam UT.

20. An Inspector observes insulation clips being welded to a type 316SS vessel.
Which of the following clips may cause liquid ME of the vessel?
a) Galvanized CS
b) CS
c) Aluminum
d) Type 410SS.

21. Prevention of HTHA is usually achieved by using?

a) Alloy steels with chromium & moly added to increase carbide stability.
b) Austenitic SS cladding on carbon steel equipment
c) High-nickel alloy steels selected in accordance with API recommended
practice 941
d) Carbon and moly steels where carbon steel limits are surpassed.
22. Which of the following is correct with regard to ammonium chloride corrosion?
a) Water wash will lead to an aggressive corrosion
b) Water wash will reduce the corrosion by flushing out the salt deposits.
c) Water wash is not effective because the corrosion rate depends only on
temp, velocity & salt concentration.
d) Water wash will increase the corrosion rate because chloride salts are
highly water soluble and therefore highly corrosive.

23. An amine unit has overhead condenser piping and a heat-exchanger condenser
constructed of titanium alloy. The most likely damage mechanism in this service
is?
a) Nitriding
b) Amine SCC
c) Metal hydriding
d) Amine corrosion.

24. Dissimilar metal weld cracks form

a) At the toe of the weld in the HAZ
b) At start/stop points in the hot pass
c) In the parent metal on the austenitic side of the weld
d) In the center of the weld.

25. Which of the following is the preferred method for detecting chloride SCC for the
process side of a pressure vessel or tank?
a) RT
b) PT
c) UT
d) Wet fluorescent MPI.

26. Which of the following is most important in determining equipments resistance to

Mechanical fatigue?
a) Material selection
b) Design of the equipment
c) Operation of the equipment
d) Frequency of inspection.

27. The presence of oxidizers in a sulfuric acid solution?

a) Has little effect on the CR
b) Will tend to inhibit the CR
c) Is desirable if temp are below 100F(38C)
d) Can greatly increase the CR.

28. During inspection of a process unit where sulfidation from high temperature H
exists in H2S streams, the inspects should?
a) Use UT or RT thickness reading to monitor for loss of wall thickness
b) Use PT & MPT to look for surface-breaking cracks
 c) Use angle beam UT to look for cracking at the mid-wall
d) Take both samples and send them to the lab for Met analysis.

29. Carbonate SCC morphology is best described as surface-breaking cracks that:

a) Develop parallel to the weld and in the weld metal and are either
transverse or longitudinal to the weld.
b) Develop parallel to the weld in the adjacent weld metal and appears step-
wise through the depth of the plate.
c) Develop parallel to the weld and adjacent to CS welds and in the adjacent
base metal and look a spider web appearance.
d) Are usually associated with weldments that are intergranular and can
continued only by Met exam.

30. Phenol (carbolic acid) corrosion is most likely to occur in ?

a) High velocity areas
b) Low velocity areas
c) Low temp areas
d) Stagnant areas

31. The most effective means of preventing caustic SCC is?

a) PWHT
b) Upgrade to 300 series SS
c) Reducing caustic concentration
d) Controlling process temp during steam outs

32. 300 Series Austenitic SS can become sensitized when heated in the range of ?
a) 400F - 675F
b) 750F -1500F
c) 1650F - 1725F
d) 2000F - 2150F

33. Flare impingement from poor burners control can cause steam generating tubes to
give rise to?
a) Vibration-induced fatigue
b) Flue gas due point corrosion
c) Steam blanketing
d) Thermal fatigue

34. Which of the following is not commonly referred to as a high-temp corrosion

mechanism?
a) Fuel ash corrosion
b) Sulfidation
c) Oxidation
d) Corrosion fatigue
35. Short-term over heating ruptures are characterized by:
a) An open fish mouth failure
b) An absence of visible plastic deformation
c) A thick walled fracture structure
d) Straight, non-branching cracks

36. A CS vessel that is in service has a history of hydrogen blistering in wet H2S
service. The most affective means of minimizing the likelihood of hydrogen
blistering damage is to?
a) Install a corrosion resistant SS clad vessel
b) Reduce the operating temp to below 300F
c) Add ammonia injection to raise the PH of the water phase above 9.0.
d) Apply PWHT of corrosion resist coating to all nozzles and weld seams.

37. Which of the following is least likely to lead to vibration-induced fatigue?

a) High-pressure drop control valves & steam-reducing stations
b) Small bore piping near pumps & compressors that are not sufficiently
gusseted
c) Safety relief valves subject to chatter, premature pop-off, fretting & failure
to operate properly
d) Cantilevered, heavily weighted small-bore instrumentation branch
connection to process equipment.

38. CS is susceptible to ammonia SCC in

a) Anhydrous ammonia <0.2%water
b) Anhydrous ammonia >0.2%water
c) Ammoniated water system
d) Moist ammonia above 200F

39. A gray cast iron pipe is exposed to external, acidic, sulfate containing water. After
abrasive blasting for painting, large soft blanket spots are find. The pipe has most
likely experienced?
a) Graphitic corrosion
b) Pitting corrosion
c) Galvanic corrosion
d) Graphitization.

40. CUI can be minimized by

a) Corrosion resistant and Insulation barriers
b) By using calcium silicate insulation
c) By making RBI
d) Operating above 250F
41. Which of the following states about Reheat cracking is most occur during:
a) Multiple PWHT
b) PWHT or High temp

42. Carbolic acid is mostly occur?

a) High velocity
b) Low velocity
c) Low temp
d) High temp

43. Phosphoric acid corrosion due to

a) At temp below due point
b) In equipment exposed to sulphur content.

44. Hydrofluoric acid

a) < 300
b) Temp > corrosion <
c) 300 to 400
d) Temp < corrosion >