Practice Free API-571 Corrosion and Materials Professional Exam Questions Answers With Explanation

According to API RP 571, in the section on "Chloride Stress Corrosion Cracking (Cl-SCC)", several critical factors are outlined that contribute to the initiation and propagation of this mechanism. The document states:

“Critical factors include the presence of chlorides (even at ppm levels), oxygen, elevated temperatures, tensile stress, and susceptible materials such as austenitic stainless steels and some nickel alloys.”

“Oxygen is an accelerant and promotes pitting that can lead to SCC initiation.”

(Reference: API RP 571, 3rd Edition, Section 4.2.2.2)

Therefore, the presence of oxygen is a well-documented critical factor in Cl-SCC. It acts in conjunction with chlorides to initiate localized pitting, which then progresses into cracking. Hence, option B is the correct choice.

From API RP 571 Section 5.1.2.7 (Amine Stress Corrosion Cracking) and API RP 945 (Avoiding Environmental Cracking in Amine Units):

MEA (Monoethanolamine) systems are most aggressive due to:

“Their high reactivity and degradation potential producing corrosive by-products that promote cracking.”

API RP 945:

“SCC in carbon steel is most frequently reported in MEA units, especially where localized concentrations of heat-stable salts exist.”

Thus, Option C (MEA) is the correct answer due to its high SCC risk.

API RP 571 describes Temper Embrittlement as:

“A metallurgical degradation mechanism that leads to a reduction in fracture toughness due to long-term exposure in the temperature range of 650°F to 1070°F (345°C to 575°C).”

“It affects Cr-Mo steels and is not easily detected except by impact testing.”

Therefore, option C most accurately defines the condition based on the recognized API description.

API RP 571 states under the section Phosphoric Acid Corrosion:

“Corrosion usually occurs when the acid dries out and forms concentrated phosphoric acid deposits, which are very aggressive to carbon steel.”

“Drying or concentration occurs due to poor flow distribution or operational upsets. Localized areas may experience acid concentration due to vaporization.”

(Reference: API RP 571, Section 4.3.3.8 – Phosphoric Acid Corrosion)

Therefore, the most aggressive corrosion occurs when the acid dries out, making option D correct.

From API RP 571 Section 5.3.3.2 (Caustic Corrosion):

“Caustic corrosion, also known as caustic gouging, occurs in boiler systems when caustic concentrates in under-deposit areas or due to improper steam drum and boiler water design. Good design and water treatment practices are key preventive measures.”

Temperature control or acid injection are not practical or effective mitigation techniques. Design considerations—such as proper water flow, material selection, and minimizing deposits—are essential.

Hence, the correct answer is Option C.

API RP 571 – Hydrogen Stress Cracking – HF Acid Service:

“HF acid environments can cause hydrogen stress cracking (HSC) in carbon steel, particularly in areas with high hardness or residual stress.”

“This is distinct from general corrosion and requires specific inspection focus.”

So, option A is correct.

Erosion and erosion-corrosion are mechanical degradation mechanisms enhanced by fluid motion, and typically result in directional or flow-oriented metal loss patterns.

According to API RP 571 Section 5.4.2 (Erosion and Erosion/Corrosion):

“Erosion typically results in localized thinning, often described as grooves, gullies, or horseshoe-shaped patterns... The metal loss is directional and may occur in elbows, tees, reducers, and pumps.”

Hence, Option C (grooves and gullies) most accurately describes erosion and erosion-corrosion characteristics.

Comprehensive and Detailed Explanation From Exact Extract:

Amine stress corrosion cracking is most frequently associated with rich amine services, where:

Acid gas loading (H?S / CO?) is high

Corrosive contaminants and degradation products are present

Higher operating temperatures and stresses exist

Per API RP 571, cracking is far more common in rich amine systems than in lean amine circuits.

Why the other options are incorrect:

Lean amine has lower acid gas content and reduced SCC risk

SCC is not limited to low temperatures

Concentration alone is not the dominant factor

Referenced Documents (Study Basis):

API RP 571 – Section on Amine Stress Corrosion Cracking

According to API RP 571 Section 5.3.2.3 (Spheroidization):

“Spheroidization is the transformation of the microstructure of carbon and low alloy steels when exposed to elevated temperatures for long durations. The rate of spheroidization depends on temperature, prior microstructure, and exposure time... The microstructure becomes less effective at carrying loads, and strength is reduced.”

Key influencing factors for the rate of spheroidization are:

Temperature (higher accelerates the process),

Microstructure (initial phase distribution and morphology).

Pressure and hydrogen partial pressure are not relevant for this transformation, nor is stress a primary driver.

Therefore, Option D (temperature and microstructure) is correct.

Comprehensive and Detailed Explanation From Exact Extract:

According to API RP 571, ammonium bisulfide (NH?HS) corrosion typically occurs in high-velocity, wet sour service, such as hydroprocessing reactor effluent systems. The damage is characterized by localized wall thinning, often with highly irregular corrosion profiles that vary with flow regime.

API RP 571 emphasizes that the most effective inspection techniques for NH?HS corrosion are those capable of:

Detecting localized thinning

Identifying corrosion patterns related to flow velocity

Covering large areas efficiently

Ultrasonic scanning (C-scan) and profile radiography are specifically recommended because they:

Reveal localized and preferential metal loss

Allow comparison between high- and low-velocity zones

Are far superior to spot UT, which may miss localized attack

Referenced Documents (Study Basis):

API RP 571 – Section on Ammonium Bisulfide Corrosion

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Comprehensive and Detailed Explanation From Exact Extract:

According to API RP 571, surface decarburization is a metallurgical degradation mechanism that occurs when carbon is removed from the surface layers of steel due to exposure to oxidizing environments at elevated temperatures. This results in a carbon-depleted surface layer.

Carbon is a primary strengthening element in carbon and low-alloy steels. When carbon is lost from the surface:

Hardness and tensile strength are reduced

Creep resistance and load-carrying capability decrease

The component becomes more susceptible to plastic deformation and failure under stress

API RP 571 states that decarburization leads to loss of mechanical strength, especially critical in high-temperature service, where components already operate close to material limits.

Why the other options are incorrect:

Option A: Stress cracking is not the primary effect; loss of strength is.

Option C: Decarburization does not directly accelerate oxidation or sulfidation, although both may coexist.

Option D: This is incorrect; decarburization is considered detrimental in high-temperature applications.

Referenced Documents (Study Basis):

API RP 571 – Section on Decarburization and Metal Dusting

API Corrosion and Materials Study Guide

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According to API RP 571 and API RP 583:

“The most effective mitigation of CUI is the use of appropriate coatings underneath the insulation, which are resistant to moisture and chloride ingress.”

“Inspection and insulation selection are also important but are secondary controls.”

(Reference: API RP 571, Section 4.3.4 – Corrosion Under Insulation; API RP 583)

Hence, option D is correct.

Comprehensive and Detailed Explanation From Exact Extract:

Per API RP 571, deaerators often operate in environments where concentrated caustic solutions can form locally due to oxygen scavengers and water chemistry control additives.

When postweld heat treatment (PWHT) is not performed:

High residual welding stresses remain

Conditions are ideal for caustic stress corrosion cracking (Caustic SCC)

API RP 571 identifies deaerators as classic examples of equipment that has experienced caustic SCC when PWHT was omitted.

Referenced Documents (Study Basis):

API RP 571 – Section on Caustic Stress Corrosion Cracking

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Comprehensive and Detailed Explanation From Exact Extract:

According to API RP 571, hydrofluoric (HF) acid corrosion rates increase significantly once operating temperatures exceed approximately 150 °F (65 °C).

Key points noted in API RP 571:

Below ~150 °F, corrosion rates are relatively low due to formation of protective iron fluoride films.

Above 150 °F, these films become unstable.

Corrosion rates increase rapidly with temperature, especially under high velocity and water contamination conditions.

Why the other options are incorrect:

Option A (100 °F) is below the threshold for accelerated corrosion.

Option C and D are well above the onset temperature but are not the minimum threshold.

API RP 571 explicitly identifies 150 °F (65 °C) as the critical temperature where corrosion acceleration begins.

Referenced Documents (Study Basis):

API RP 571 – Section on Hydrofluoric Acid Corrosion

API Alkylation Unit Corrosion Study Guide

As per API RP 571 on Sigma Phase Embrittlement:

“Sigma phase embrittlement occurs in stainless steels and nickel-based alloys due to the formation of a brittle intermetallic phase in the temperature range of 1050°F to 1650°F (565°C to 900°C).”

“This damage mechanism is not easily detected through surface or hardness testing and typically requires metallographic examination to confirm the presence of sigma phase in the microstructure.”

Metallographic testing allows clear identification of sigma phase particles and is thus the most reliable method, making option D correct.

From API RP 571 Section 5.1.2.5 (Polythionic Acid Stress Corrosion Cracking):

“PTASCC typically occurs on the surface of stainless steels that have been sensitized. Since cracks are open to the surface, liquid penetrant testing (PT) is the most effective detection method.”

Magnetic particle testing is ineffective for non-magnetic materials like austenitic stainless steels.

UT is less effective for fine surface-connected cracks.

Hardness testing is unrelated to detecting cracking.

Thus, Option C (Liquid penetrant testing) is the correct and preferred method for detecting PTASCC.

According to API RP 571 Section 5.3.2.1 (Creep):

“Creep damage is exponentially dependent on temperature. A small increase in temperature (e.g., 25°F or 15°C) can reduce remaining life by more than half. This is because the creep rate increases rapidly with temperature, especially above design limits.”

Stress is a contributing factor, but the dominant and most sensitive variable is temperature.

Thus, Option C (increase in temperature of 25°F/15°C) is the correct answer.

API RP 571 states under Chloride Stress Corrosion Cracking (Cl-SCC):

“Nickel contents above approximately 35% provide significant resistance to chloride stress corrosion cracking. Alloys such as Alloy 625 and Alloy 825 exhibit excellent resistance.”

“Austenitic stainless steels with lower nickel contents, such as 304 and 316, are more susceptible to Cl-SCC.”

Hence, option C (35%) is correct.

API RP 571 under Sulfidation (High Temperature Sulfidic Corrosion) recommends:

“Thickness monitoring using ultrasonic testing (UT) or radiographic testing (RT) is the most common method for detection of wall loss due to sulfidation.”

“Sulfidation results in uniform thinning, especially in low Cr steels in hydrogen/H?S environments.”

(Reference: API RP 571, Section 4.2.1.1 – Sulfidation)

Thus, option A is the most appropriate and effective inspection method.

Comprehensive and Detailed Explanation From Exact Extract:

According to API RP 571, corrosion in cooling water systems often increases at low flow velocities due to:

Stagnation

Deposit formation

Increased risk of underdeposit corrosion and MIC

Higher velocities tend to:

Sweep away deposits

Maintain protective films (within erosion limits)

Therefore, decreasing velocity is strongly associated with increased corrosion risk.

Referenced Documents (Study Basis):

API RP 571 – Section on Cooling Water Corrosion

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Comprehensive and Detailed Explanation From Exact Extract:

According to API RP 571, graphitization is a high-temperature degradation mechanism that occurs in carbon and carbon-molybdenum steels exposed for long periods at temperatures typically above 800 °F (425 °C).

In this process:

Iron carbides decompose into free graphite nodules

The steel loses strength, ductility, and pressure-retaining capability

Failures can occur without significant wall loss

Graphitization does not occur in aluminum, stainless steels, or nickel-copper alloys such as Monel.

Referenced Documents (Study Basis):

API RP 571 – Section on Graphitization

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API RP 571 and RP 939-C define sulfidation conditions as:

“Sulfidation of iron-based alloys generally becomes significant at temperatures above 500°F (260°C) in hydrocarbon streams with sulfur but without hydrogen.”

“For hydrogen-containing environments, this threshold may be reduced to 450°F (230°C).”

(Reference: API RP 571, Section 4.2.1.1 – Sulfidation; API RP 939-C, Section 3.1)

Therefore, the correct answer is D.

From API RP 571, under Cooling Water Corrosion:

“If proper water treatment is not feasible or consistently maintained, upgrading the metallurgy of exchanger tubes to more corrosion-resistant materials such as stainless steel or titanium may be necessary.”

“This is especially important in seawater or brackish water cooling applications or in once-through systems.”

(Reference: API RP 571, Section 4.3.1.1 – Cooling Water Corrosion)

Thus, the most effective long-term solution in cases of uncontrolled water quality is to upgrade metallurgy, making option C correct.

API RP 571, under Chloride Stress Corrosion Cracking, notes:

“Cracking often appears as highly branched or ‘crazed’ networks on the surface, especially in austenitic stainless steels exposed to chlorides under tensile stress.”

“These cracks often initiate in the heat-affected zones or cold-worked areas and are intergranular in nature.”

This signature ‘crazed’ appearance with branching is diagnostic of Cl-SCC, making option C the correct and most descriptive answer.

API RP 571 under Oxidation states:

“Resistance to oxidation is improved significantly by increasing chromium content, as it promotes the formation of a protective chromium oxide (Cr?O?) layer.”

“Nickel may aid in high-temperature strength but does not directly improve oxidation resistance like chromium does.”

(Reference: API RP 571, Section 5.1.1 – Oxidation)

Hence, option A is correct.

Comprehensive and Detailed Explanation From Exact Extract:

Concentration Cell Corrosion is defined in API RP 571 as a form of electrochemical corrosion driven by differences in concentration of corrosive species, most commonly oxygen, under deposits or within crevices.

This type of corrosion typically occurs:

Beneath deposits, scale, or fouling

In stagnant zones or crevices

Where oxygen concentration differs between adjacent areas

The area with lower oxygen concentration becomes anodic and corrodes preferentially, while the oxygen-rich area becomes cathodic.

Why the other options are incorrect:

Option B describes galvanic corrosion, not concentration cell corrosion.

Option C refers to high-temperature sulfidation, unrelated to concentration gradients.

Option D describes mechanical damage mechanisms, not electrochemical corrosion.

API RP 571 clearly categorizes concentration cell corrosion as being associated with deposits or crevice conditions, making Option A the correct description.

Referenced Documents (Study Basis):

API RP 571 – Section on Concentration Cell and Crevice Corrosion

API Corrosion Fundamentals Study Guide

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According to API RP 571, under Naphthenic Acid Corrosion (NAC):

“The most severe corrosion is typically found in areas of high velocity and turbulence, such as at pump around nozzles, transfer lines, elbows, reducers, and orifices.”

“NAC is characterized by uniform thinning and can accelerate significantly where flow-induced erosion is present.”

(Reference: API RP 571, Section 4.3.4.1 – Naphthenic Acid Corrosion)

This clearly establishes that high velocity and turbulence increase NAC severity, making option D correct.

API RP 571 explains the typical location of dissimilar metal weld (DMW) cracks as follows:

“DMW cracking usually occurs in the heat-affected zone (HAZ) on the ferritic side of the weld.”

“The difference in thermal expansion coefficients, grain structures, and creep rates between the ferritic and austenitic materials contributes to the development of high stress and strain concentrations in the HAZ of the ferritic material.”

(Reference: API RP 571, Section 4.2.1.6 – Dissimilar Metal Weld Cracking)

Thus, these cracks do not occur in the center of the weld or on the austenitic side, but rather at the ferritic HAZ, making option A correct.

Comprehensive and Detailed Explanation From Exact Extract:

In HF Alkylation units, API RP 571 identifies certain residual alloying elements in carbon steel that can significantly increase corrosion rates in HF acid service.

The most detrimental residual elements are:

Chromium (Cr)

Copper (Cu)

Nickel (Ni)

These elements:

Disrupt formation of protective iron fluoride films

Increase general and localized corrosion rates

Are tightly controlled in carbon steel specifications for HF service

Referenced Documents (Study Basis):

API RP 571 – Section on Hydrofluoric Acid Corrosion

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API RP 571 defines Hydrogen Embrittlement as:

“Improper PWHT can trap hydrogen within the microstructure of carbon steel or fail to relieve residual stresses, both of which increase the risk of hydrogen embrittlement.”

“Moisture in electrodes contributes to hydrogen-induced cracking, but embrittlement from atomic hydrogen is more directly tied to heat treatment and microstructure.”

Thus, option D is the most accurate.

As per API RP 571 Section 5.3.2.3 (Spheroidization):

“Spheroidization is the transformation of the microstructure of steels into spherical carbides, leading to reduced strength and hardness, especially after extended high-temperature exposure. It’s commonly seen in carbon and low alloy steels in refining heaters and reactors.”

It reduces strength and sometimes hardness.

It increases ductility, not reduces.

SCC potential is not directly tied to this change.

Therefore, Option D (Loss of strength) is correct.

Comprehensive and Detailed Explanation From Exact Extract:

According to API RP 571, chloride stress corrosion cracking (Cl-SCC) of austenitic (300 series) stainless steels becomes a credible concern when:

Chlorides are present

Tensile stress exists

Metal temperatures exceed approximately 140 °F (60 °C)

Below this temperature, Cl-SCC is far less likely, while susceptibility increases rapidly above this threshold.

Referenced Documents (Study Basis):

API RP 571 – Section on Chloride Stress Corrosion Cracking

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Comprehensive and Detailed Explanation From Exact Extract:

Per API RP 571, sulfidation corrosion is controlled by three primary variables:

Sulfur species concentration (e.g., H?S, sulfur compounds)

Operating temperature

Metallurgy, especially chromium content

Chromium significantly improves sulfidation resistance by forming protective sulfide scales. All three factors must be considered in RBI assessments.

Referenced Documents (Study Basis):

API RP 571 – Section on Sulfidation Corrosion

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From API RP 571 and RP 932-B:

“In hydroprocessing reactor effluent systems, the most common corrosion mechanism is ammonium bisulfide (NH?HS) corrosion, which forms in the presence of hydrogen sulfide and ammonia.”

“NH?HS attacks carbon steel aggressively under turbulent flow and at low pH.”

Correct answer is B – ammonium bisulfide corrosion.

According to API RP 571, under Caustic Stress Corrosion Cracking (Caustic Embrittlement):

“Cracking occurs in stressed components exposed to caustic (e.g., sodium hydroxide).”

“The most effective mitigation strategy is postweld heat treatment (PWHT), which relieves residual stress that promotes cracking.”

“Upgrading materials or controlling concentration may help, but do not replace stress relief.”

(Reference: API RP 571, Section 4.2.2.3 – Caustic SCC)

Thus, PWHT is the most effective prevention technique, making option A correct.

API RP 751 (referenced in RP 571) lists materials appropriate for HF acid alkylation service. It specifies:

“Chrome-moly steels such as ASTM A-193 B5 (5% Cr) bolts are preferred for their resistance to HF acid-induced cracking.”

“Standard low alloy steels (e.g., B7) are not considered adequately resistant.”

(Reference: API RP 571 summary & API RP 751, Section 5.6.3 – Bolting Materials)

Therefore, the correct and industry-approved answer is option A.

According to API RP 571 Section 5.2.1 (Fatigue – High Cycle and Low Cycle):

“Unsupported small-bore attachments like vents and drains are prone to high-cycle mechanical fatigue due to vibration. These attachments experience cyclic stress, especially near welds or bends.”

Thermal overload is unlikely without over-temperature data.

SSC (Option C) requires a wet H2S environment, which is not indicated.

Weld defects may contribute but are less likely the root cause without other signs.

Hence, mechanical fatigue (Option A) is most probable in this configuration.

API RP 571 states under Galvanic Corrosion:

“Because galvanic corrosion usually manifests as thinning of the more anodic metal, ultrasonic thickness measurements taken near dissimilar metal joints are an effective way to detect this type of internal corrosion.”

“Surface NDE techniques like liquid penetrant or magnetic particle testing are not effective for detecting wall loss.”

Thus, option D (ultrasonic thickness testing) is correct.

API RP 945, dedicated to environmental cracking in amine units, states:

“Carbon steel is widely used in amine systems but is particularly susceptible to localized corrosion, under-deposit corrosion, and stress corrosion cracking, especially in high-pressure or rich amine environments.”

“Proper control of amine quality, oxygen ingress, and temperature is critical to avoid accelerated corrosion in carbon steel equipment.”

Thus, carbon steels are the most commonly affected materials, making option C correct.