API-571 Mockup Test-01-Questions

Mockup Questions Test-1

1. -----------------is a change in the microstructure of certain carbon steels and 0.5Mo steels
after long-term operation in the 800oF to 1100oF (427oC to 593oC) range that may cause
a loss in strength, ductility, and /or creep resistance.

A. Graphitization
B. Spherodization
C. Lamellar tearing

2. At elevated temperatures, the carbide phases in C-0.5Mo steels are unstable and may
decompose into graphite nodules. This decomposition is known as

A. Graphitization
B. Spheridization
C. Hot cracking

3. Following are the materials more likely affected by graphitization

A. Carbon and Molybedenum steels

B. Carbon-0.5Mo
C. C-1.5Mo

4. -----------alloying element added to eliminate graphitization and what percentage

A. Nickel,0.1%
B. Chromium,0.7%
C. Chromium, 1.5%
D. Nickel,1.0%

5. The phenomena of formation of spheroidal and nodular formation due to the unstability of
carbide phases are
A. Spherodization and graphitization
B. Martensitic and bainitic
C. Annealing and normalizing

6. The rate of speroidization depends upon

A. Temperature
B. Exposure time
C. Temperature and initial microstructure
D. Metal chemistry
E. All of the above

7. Following are the type of heattreatment to steels which will resist in formation of
spheroidization
A. Annealed steels, fine grained steels, aluminium killed steels
B. Normalised steels, coarse grained steels, silicon killed steels
C. Annealed steels, coarse grained steels, silicon killed steels
D. Normalised steels, fine grained steels, aluminium killed steels

8. following is the suitable preventive action to avoid spheroidization

A. minimizing long-term exposure to elevated temperatures.
B. long-term exposure to elevated temperatures
C. to expose to a temperature of 452C constantly.

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9. Temper embrittlement is a metallurgical change that is not readily apparent and can be
confirmedthrough
A. impact testing.
B. Hardness testing
C. Bend testing
D. Tensile testing

10. Temper embrittlement cannot be prevented for the existing materials if,
A. contains critical levels of the embrittling impurity elements and is exposed in the
embrittling temperature range.
B. Contains non embrittling impurity elements and not exposed to high temperature
range
C. Contains critical levels of the embrittling impurity elements and not exposed to
high temperature range
D. Contains non embrittling impurity elements and exposed to high temperature
range

11. To minimize the possibility of brittle fracture during startup and shutdown, many refiners
use

A. A Volumetric sequence to limit system volume to about 25 percent of the

maximum design capacity.
B. A controlled temperature sequence to limit system temperature to about 25
percent of the maximum design temperature.
C. A pressurization sequence to limit system pressure to about 25 percent of the
maximum design pressure for temperatures below a Minimum Pressurization
Temperature (MPT).
D. None of the above

12. A common method of monitoring the temper embrittlement is

A. to install blocks of original heats of the alloy steel material inside the reactor and
samples are removed periodically for impact testing.
B. to install blocks of original heats of the alloy steel material inside the reactor and
samples are removed periodically for hardness testing.
C. to install blocks of original heats of the alloy steel material inside the reactor and
samples are removed periodically for tensile testing.
13. Oxidation of carbon steel becomes significant above about
A. 800 F
B. 1500 F
C. 1000 F
D. 427 F

14. Generally, Oxidation resistance of carbon steel and other alloys

A. Increases with carbon content
B. Increases with chromium content
C. Decreases with carbon content
D. Decrease in chromium content

15. Oxidation of 300 Series and Nickel alloys will generally have an appearance of
A. Thick oxide scales with general thinning
B. Very thin dark scale
C. Alligator hide appearance
D. Shiny appearance

16. Other oxidation resistant alloys are - Aluminum & Silicon, but their concentrations have
adverse effect on mechanical properties

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17. Phenomenon where steel losses its strength due to removal of carbon and carbides
leaving only iron matrix is called
A. Carburization
B. Metal dusting
C. Oxidation
D. Decarburization

18. Materials affected by decarburization are

A. Carbon steels
B. Low alloy steels
C. 300 SS series stainless steels
D. Both a & b above
E. All of the above

19. Appropriate inspection method to confirm decarburization

A. Profile radiography
B. Hardness testing
C. Ultrasonic thickness measurement
D. Visual Inspection
E. All of the above

20. The metal which currently known to be highly immune to metal dusting in all conditions is
A. 300 Series SS
B. Nickel base alloys
C. High chrome alloys steels
D. All of the above
E. None of the above
21. Carburization of the tube surface, especially on austenitic alloys will -----------corrosion
resistance and increase tube wastage rates.
A. Increase
B. Decrease
22. Steam generating pressure which is nearly immune to fuel ash corrosion on water wall
side is
A. below 1800 psi
B. above 1800 psi
23. For oil-fired boilers, fuel oils that do not contain ----------- are less prone to liquid ash
corrosion.
A. Vanadium
B. Potassium
C. Sodium & Potassium iron sulfates
D. None of the above
24. The surface of steel with “alligator-hide” appearance as shallow grooves which
penetrates into steel in cross-hatched pattern depicts a corrosion mechanism of
A. Graphitization
B. Oxidation
C. Erosion
D. Fuel ash corrosion
25. Above --------- temperature preferential grain boundary NITIDING may lead to micro
cracking and embrittlement.

A. 300 F (150C)
B. 770F (410C)
C. 550 F (288C)
D. 900 F (482 C)

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26. Nitrogen diffuses into the surface and forms -------------of iron nitrides (Fe3N or Fe4N) that
can only be confirmed by metallography.

A. Globular particles
B. Needle-like particles
C. Craze – non directional particles
27. Nitriding is usually confined to the surface of most components and will have a

A. Dull, dark gray appearance.

B. Black – oxidized scaly appearance
C. Alligator hide appearance
D. Glassy – flake like appearance
28. During Nitriding in a very advanced stage the hardness of the surface will be

A. 200 - 225 BHN or Higher

B. 300 - 400 BHN or higher
C. 225 - 325 BHN or higher
D. 400 - 500 BHN or higher

29. Following are the materials susceptible to brittle fracture

A. Carbon steels
B. Low alloy steels
C. 400 series steels
D. All of the above

30. …………………. sections also have a lower resistance to brittle fracture due to higher
constraint which increases triaxial stresses at the crack tip.
A. Thinner sections
B. Thicker sections
C. Heavy wall thickness sections
D. Both B & C

31. Brittle fracture can occur during ambient temperature hydrotesting due to
A. high stresses and low toughness at the testing temperature.
B. low stresses and high toughness at the testing temperature.
C. low stresses and low toughness at the testing temperature.
D. None of the above

32. Cracks will typically be straight, non-branching, and largely devoid of any associated
plastic deformation. The appearance is associated with
A. Ductile fracture
B. Fracture due to shear
C. Brittle fracture
D. None of the above
33. Thermal fatigue cracks APPEARANCE AND PROPAGATION WILL BE
A. Transverse and circumferential to the stress and they are usually dagger-
shaped, transgranular, and oxide filled
B. longitudinal to the stress and they are usually dagger-shaped, transgranular, and
oxide filled
C. Transverse and longitudinal to the stress and they are usually dagger-shaped,
transgranular, and oxide filled
D. All of the above
34. Effective methods for intrusive inspection of thermal fatigue cracks
A. MT & PT
B. MT & UT
C. PT & UT

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D. All of the above

35. preferred method used for non-intrusive inspection for internal cracking due to thermal
fatigue
A. Automated UT
B. External SWUT
C. WFMT
D. None of the above
36. -----------------------is the limitation area which can be skipped in External SWUT in vessels
A. Nozzle examination prevented by reinforcing pads
B. Internal parts weld areas
C. Internal welds on shell
D. All of the above
37. Environments in the order of high corrosion rates to low corrosion rates due to
atmospheric corrosion.
A. Industrial environments with acid contaminants (20mpy) – Marine environments
(10mpy) – Moderate humid inland locations (3mpy) – Dry rural environments
(<1mpy)
B. Dry rural environments (20mpy) - Marine environments (10mpy) - Industrial
environments with acid contaminants (3mpy) - Moderate humid inland locations
(<1mpy)
C. Dry rural environments (20mpy) - Industrial environments with acid contaminants
(10mpy) - Moderate humid inland locations (3mpy) - Marine environments
(<1mpy)
D. Marine environments (20mpy) - Industrial environments with acid contaminants
(10mpy) - Moderate humid inland locations (3mpy) - Dry rural environments
(<1mpy)
38. On an un-insulated surface atmospheric corrosion rates on surface increase with
temperature up to _______,
A. 101 deg C
B. 121 deg C
C. 251 deg C
D. 171 deg C
39. Atmospheric corrosion can be accelerated by except
A. Chlorides
B. H2S
C. Airborne contaminants from cooling tower drift and fly ash from furnace stacks
D. Pigeon droppings
E. None of the above
40. A potable water carbon steel piping was passing through jetty area, corrosion with a iron
oxide scale (red rust) was seen on the surface at sleeper supports and at the paint
peeled off areas, what form of corrosion you can conclude.
A. Cooling water corrosion
B. Galvanic corrosion
C. Sea water corrosion
D. Atmospheric corrosion.
41. At high operating temperatures the cracking of dissimilar materials occur at
A. Austenitic SS side
B. Ferritic material side
C. Both A&B
D. None of the above

42. The coefficients of thermal expansion between ferritic steels and 300 Series SS differ by
A. 30% or more
B. 10% or less
C. 20% or more
D. None

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43. The temperature at which carbon diffusion becomes a concern for carbon steels and low
alloy steels is
A. Above 427 C to 510 C
B. Above 600 C
C. Below 400 C
D. None of the above

44. Ferritic/austenitic joints can generate significant thermal expansion/thermal fatigue

stresses at temperatures greater than
A. 300 C
B. 260 C
C. 100 C
D. None of the above
45. Electric resistance welds in brackish water service carbon steel piping may suffer more
likely with ________ on welds / HAZ
A. Cooling water corrosion
B. Stress corrosion cracking
C. Erosion
D. Corrosion fatigue
46. To prevent cooling water corrosion, process side inlet temperature to be designed below
A. 57 C
B. 75 C
C. 66 C
D. 46 C
47. Periodic calculation of U-factors for heat exchangers is done to
A. Identify tube thinning / wall loss
B. Identify Scaling or fouling
C. Identify Pitting corrosion on OD at baffle location
D. Identify cracking at U-bend areas
48. Preferably cooling water to be used on shell side in a cooling water exchanger / coolers
A. True
B. False
49. Fatigue fracture / cracking will be evidenced by
A. Ductile deformation
B. Very little plastic deformation
C. Most often transgranular
D. b & c
50. Cross-section of the cracks occurred by corrosion fatigue in the water side of buck-stay
attachments in cycling boilers will tend to be of
A. Needle & Sharp edge
B. Bulbous with numerous lobes
C. Craze cracks
D. none of the above
51. Crack tips in cycling boiler water side of buck-stay attachments occurred due to corrosion
fatigue are
A. Sharp edge & Intergranular & Oxide filled
B. Blunt edge , Intragranular & Oxide filled
C. Sharp edge & Intragranular & Oxide filled
D. Blunt edge & Intergranular & Oxide filled
52. To prevent corrosion fatigue failures in rotating equipment mitigation steps are
A. Modify the corrosive environment by using coatings and/or inhibitors.
B. Minimize galvanic couple effects.
C. Use more corrosion resistant materials
D. All of the above
53. To prevent corrosion fatigue failures in De-aerators preventive steps are
A. Proper feed water and condensate chemical control.

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B. Minimize residual welding and fabrication stresses through PWHT.

C. Minimize weld reinforcement by grinding weld contours smooth.
D. All of the above
54. Methods to prevent corrosion fatigue failures in cycling boilers are
A. Slow start-up to minimize differential expansion strains
B. Sudden start-up and shutdown
C. Startup with proper boiler water chemistry control
D. a & c
55. General method of NDT to detect cracks in de-aerators occurred due to corrosion fatigue
A. ECT
B. RT
C. SWUT
D. WFMT
56. In cycling boilers, due to corrosion fatigue phenomenon cracking may occur at highly
stressed regions, particularly at corners of buck-stay attachments, these areas to be
inspected by _________ techniques.
A. VT / RT
B. UT / EMATS
C. PT / WFMT
D. VT / SWUT
57. Maintaining the pH value ___ can reduce corrosion in the steam condensate system.
A. above 3
B. below 4
C. above 6
D. between 3–6
58. The dew point of sulfuric acid depends on the concentration of sulfur trioxide in the flue
gas, typical temperature is about
A. 54 deg C
B. 87 deg C
C. 138 deg C
D. 149 deg C
59. The dew point of hydrochloric acid depends on the concentration of hydrogen chloride,
typical temperature is about
A. 54 deg C
B. 87 deg C
C. 138 deg C
D. 149 deg C
60. Micro biological organisms which induce corrosion in steels can survive in temperatures
_______ , and these organisms thrive on different nutrients including inorganic
substances (e.g., sulfur, ammonia, H2S) and inorganic substances (e.g., hydrocarbons,
organic acids). In addition, all organisms require a source of carbon, nitrogen and
phosphorous for growth.
A. -17 to 135 deg C
B. - 4 to 121 deg C
C. 0 to 100 deg C
D. 4 to 121 deg C
61. _____________is most often found in heat exchangers, bottom water of storage tanks,
piping with stagnant or low flow, and piping in contact with some soils.
A. Soil corrosion
B. MIC
C. Galvanic corrosion
D. Atmospheric corrosion
62. In cooling water systems, effectiveness of treatment is monitored by measuring biocide
residual, microbe counts and visual appearance, these methods are to monitor for
A. MIC
B. Soil corrosion

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C. Atmospheric corrosion
D. Galvanic corrosion
63. Underground carbon steel piping suffering with soil corrosion, severity of corrosion
depends on several factors such as operating temperature, moisture and oxygen
availability, soil resistivity, soil type, and homogeneity, Cathodic protection, stray current
drainage, coating type, age, and condition. However to estimate the soil corrosivity
frequent monitoring of ___________ is used.
A. Moisture content
B. Soil resistivity
C. Operating temperature
D. Stray currents.
64. The most effective method to protect carbon steel from soil corrosion is
A. corrosion resistant coating & CP
B. Upgrading to Stainless steel (Cr-Ni)
C. Cathodic protection
D. Special back filling.
65. In refineries, ___________ is found in some crude oils and can condense in the
atmospheric tower overhead system thereby embrittling brass, Alloy 400, titanium or
aluminum exchanger components.
A. Aluminum
B. Lead
C. Mercury
D. Arsenic
66. LME of Aluminum components has occurred in cryogenic gas plant components due to
condensation of
A. Liquid mercury
B. Sulfur
C. Chlorides
D. Arsenic
67. Damage resulting from LME will appear as brittle in an otherwise ductile material, it can
be confirmed by
A. PT
B. UT
C. RT
D. Metallography
68. The cracks resulted due to LME are of _____________ and usually filled with low melting
metal
A. Intergranular
B. Intragranular
C. Both a & b
D. None of the above
69. To prevent LME of 300 series SS, __________ components should not be welded to 300
series SS, and should be protected to avoid contact with them. Also protect from
overspray of zinc and in-organic zinc coatings.
A. Galvanized steel
B. Carbon steel
C. Low alloy steel
D. All of the above.
70. Once cracking from LME has initiated, grinding out the affected area is _____________
A. Not an acceptable fix
B. Recommended fix
C. Appropriate fix
D. None of the above
71. Nickel alloys are susceptible to a similar mechanism of LME caused by the Ni-Ni Sulfide
eutectic that forms at
A. 625F

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B. 880F
C. 1000F
D. 1157F
72. Phenomenon of loss in ductility of high strength steels due to the penetration of atomic
hydrogen can lead to brittle cracking is closely termed as
A. HTHA
B. Hydrogen embrittlement
C. Hydrogen stress cracking
D. Wet H2S damage
73. Following materials have good resistance to dilute HCL acid in many refinery applications

A. Copper-Nickel alloys
B. 300 series SS and 400 series SS
C. Alloy 400,Titanium and Some Nickel base alloys
D. All common materials

74. Dilute (aqueous) HCL can be formed from following deposits with water

A. Ammonium chloride or Amine hydro chloride salts

B. Sodium chloride and Hydrogen flouride
C. Ammonium sulfide
D. All of the above

75. HCL is not corrosive in the following process streams

A. Dry process stream

B. Wet process stream
C. Both Dry and Wet process streams
D. None of the above

76. Serious corrosion can takes place at mix points of free water and acids due to the

A. Liberation of heat
B. Absorption of heat
C. Both a and b
D. None of the above
77. …………….and……………are important aspects of a well-developed program to
minimize the effects of HCl corrosion.
A. Process and corrosion monitoring
B. Ph and design pressure
C. Water content and Ph
D. All of the above

78. High temperature H2/H2S corrosion is the sulfidation in the presence of hydrogen

A. True
B. False

79. Sulfidation or High temperature H2/H2S corrosion resistance improves with

A. Mo
B. Cr
C. Ti
D. Ni

80. Sulfidation or High temperature H2/H2S corrosion results in

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A. Uniform corrosion
B. Pitting corrosion
C. Localized corrosion
D. All of the above
81. Streams which are susceptible for NAC, Monitor __________ of the crude charge and
side streams to determine the distribution of acids in the various cuts.
A. Fe & Ni
B. Fe & TAN
C. Sulfur & Fe
D. Sulfur & TAN
82. Generally the mechanism which is difficult to distinguish with NAC is ___________
83. Typical form of corrosion occurs in a Heavy vacuum gas oil section tray and bubble caps
made of SS410 in a vacuum tower is ______________
84. ____________ is used as a solvent to remove aromatic compounds from lubricating oil
feedstock.
85. Most susceptible material for carbolic acid corrosion is Carbon steel and High resistant
material(s) for carbolic acid corrosion is ___
A. SS 316 L
B. Alloy C276
C. Alloy 400
D. SS 347 / SS 321
86. Carbolic acid corrosion is usually minimal in the treating sections when the temperature is
_____
A. <1500F
B. <2500F
C. <3500F
D. <4500F
87. Carbon steel and 304/304L stainless steel corrode rapidly in phenol service when
temperatures are
A. <150F
B. <250F
C. >350F
D. >450F
88. Dilute aqueous solutions of carbolic acid are very corrosive to the extract dryer
condensers. The percentage range of phenol dilution is
A. 20-35 %
B. 12-25%
C. 5-15%
D. 10-20%
89. Following material is primarily affected by amine corrosion

A. 300 series SS
B. Carbon steel
C. C276
D. Copper alloys

90. Which kind of amine solution is highly corrosive

A. Rich amine solution

B. Hot rich amine solution
C. Lean amine solution
D. Cold rich amine solution

91. Which kind of alkanolamine is highly aggressive for corrosion/cracking

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A. Monoethanolamine(MEA)
B. Diglycolamine(DGA)
C. Diisoprpylamine(DIPA)
D. Diethanolamine(DEA)
E. Methyldiethanolamine(MDEA)

92. Primary purpose of Amine in treating of Hydro carbon is

A. To Neutralise Acids
B. To remove H2S,CO2 and Mercaptanes
C. To remove free Water
D. To remove Hydro carbons

93. In a properly designed and operated Amine process unit following material is suitable

A. Copper alloy
B. Aluminium alloy
C. Stainless steel
D. Carbon steel

94. In rich amine service above what temperature corrosion rates increases

A. 120 deg F
B. 220 degF
C. 320 degF
D. 420 degF

95. Following materials is highly resistant in amine service

A. Nickel base alloy

B. Copper alloy
C. Aluminum alloy
D. 300 series SS

96. Leakage of oxygen results in the formation ____ and above ___ % it can significantly
increase corrosion

A. HCL, 5%
B. HSAS,2%
C. Water,10%
D. H2SO4,2%
97. In HF acid environments_________ residual elements in carbon steel may accelerate the
corrosion

A. (%Cu,%Ni,%Cr), 2%
B. (%Cu,%Ni,%C),0.2%
C. (%Cu,%Ni,%Cr),0.2%
D. (%Cu,%Ni,%C),2%

98. Due to more resistance to Hydrogen stress cracking of ASTM A193B7 following bolting
grade is suggested because of its low strength

A. B7H
B. B7M
C. B7B
D. B7L

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99. What is the recommended hardness limit for low strength carbon steels used in refinery
applications

A. <150HB
B. <200HB
C. <250HB
D. <300HB

100. Low strength carbon steels used in refinery are not generally susceptible to SCC
unless localized zones of hardness

A. >217HB
B. >227HB
C. >237HB
D. >247HB

101. Hydrogen SCC can only be confirmed by

A. Visual inspection
B. Metallography
C. SWUT
D. None of the above

102. What is the best method to determine the susceptibility to hydrogen SCC-HF

A. Chemical analysis
B. Hardness measurement
C. Metallography
D. None of the above

103. What is the recommended Carbon equivalent to avoid hydrogen SCCbest

method to determine the susceptibility to hydrogen SCC-HF

A. >0.43
B. <0.43
C. <=0.43
D. >=0.43

CE= %C+%Mn/6+%(Cr+Mo+V)/5+%(Cu+Ni)/15

104. Ammonium Bi-sulfide corrosion primarily results

A. Erosion/Erosion corrosion
105. Naphthenic acid corrosion normally takes place at temperatures

A. >150 deg F
B. >250deg F
C. >350 deg F
D. >450 deg F

106. Following element improves Naphthenic acid corrosion resistance

A. Cr
B. Ni
C. Mo

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D. Ti

107. Following element improves Naphthenic acid corrosion resistance

A. Cr
B. Ni
C. Mo
D. Ti

108. Following element in process streams inhibits NAC

A. Nitrogen
B. Oxygen
C. Water
D. Sulfur

109. For severe conditions of NAC following material is used

A. Nickel base alloys

B. SS316L
C. SS317L
D. Alloy C276

110. NAC is characterized by

A. Localized corrosion
B. pitting corrosion
C. Flow induced grooving
D. All of the above

111.NAC corrosion is associated with

A. Dry streams
B. Wet streams
C. Both Dry and wet streams

112. Severity of NAC corrosion increases with

A. Total Acidity Number(TAN) or Neutralization number

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