API 572 Study Guide

A PI 572 Study Study Guide Practice Questions  This  This follo follow wing ing is a study aid that you can use to lea learn the details and content of API f API RP-572 RP-572, I nspection of  Pressure Vessels. Vessels. There will be about about 1515-25 questions from fromthis this document on the API API 510 exam. We do not spend time in class discussi discussing this publication. bli cation. So it is i s important important that you become familiar with with thi this content in your personal study sessions. ssions. Note! The The study guide does not at this this tim time have any questions stions for API API 572 Appendix A. There will be some questions from fromAppe Appendix A on theAPI API exam.  The  The question ions in this study aid are in the same orde rder as API 572. An answer key will be prov rovide ided in clas lass. It’s t’s helpful to read read a few pages of API AP I 572 and then answer the questions stions associated ociated with with these pages. We suggest that you do this this studyguide guide at least least twice prior prior to the API API exam.

1.

Most pressure pressure vessels are subjected to internal nternal or external pressure pressure that exceeds: a) b) c) d)

5 psig. 15 psig. 25 psig. 50 psig.

2.

External pre press ssure ure is usua usuallly caus cause ed by a vacuu vacuum m or by usi using a ____________________ vesse ssel.

3.

Vesse essell shell rings rings arenormally all y made ade by: a) b) c) d) e)

4.

Shells Shells constructe constructed d with with multiulti -layers (a number of thin cyli cylindrical sections) ctions) arenormally all y used for vessels having: a) b) c) d)

5.

Carbo Carbon n Steel Coppe Copper A lloys ll oys Titanium itanium

____ __ ____ ____ ____ ____ __ ____ ____ ____ ________ __ __

Cooling Wate Water Sea Sea Wate Water Most ost Comm Common Material

What is theprim primary purpose purpose for installing a lining on theinside of a vesse vessel? a) b) c) d)

7.

high high design design temperatures. high high desi design pressures. pressures. exotic materials. rials. a small diam diameter.

Match the material rial with with theservice: rvice: A. B. C.

6.

roll rol ling plate plate at ambien bientt temperatures. peratures. rolling plate at elevated temperatures. roll rol ling plate at either el elevated evated or ambient bient temperatures. peratures. forging. casting and machining.

Resist corrosi corrosion I mprove heat heat transfer transfer I mprove flui fluid d flow fl ow by decreasing the fricti riction on inside inside thevesse vessel Minim nimized effort to clea clean vesse vessel at future turnaroun turnarounds ds

When hen is a pressure pressure vessel shell normally all y madefrom an alloy all oy material? rial? a) b) c) d)

Corrosive Corrosive service rvice High operating pressures High operating tempe temperatures ratures Either high operating pressure or high high operating rating tem temperature perature

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September 2005

A PI 572 Study Study Guide Practice Questions 8.

9.

L ist four type types of Metal tallic li c L iners. iners. a)

______________ _______ ______________ ______________ ____________ _____ c) ______________ _______ ______________ ______________ ____________  _____ 

b)

 _________________________________ d) _________________________________ 

What are thetwo prim primary purposes purposesfor non-met non-metall alliic liners? a) b) c) d) e)

10.

What is the most common feature of vessel vessels that operatewith with a vacuum? a) b) c) d)

11.

API 660, ASME Sect Section ion VII I , TEMA TE MA API 661, ASME ASM E Sec Section tion VII VI I I , TEMA TEM A API 660, API API 661, TEMA TE MA API 660, API API 661,. ASME ASM E Sect Section ion VII VI I I,

All vess vesse el manufact anufacture urers that bui build vess vesse els to A SM SME E Section Section VI II must must have: ve: a) b) c) d)

15.

A SME B&PV B&PV CodeSect Section ion VI II Division Division 1. ASME B&PV Code Code Sect Section ion VI II Division 2 API/ASME Vessel Code.  TEMA

What codes are used when constructing constructi ng a heat exchanger that that is used in the petrochem petrochemical industry? industry? a) b) c) d)

14. 14.

baffle. demister mat. impinge pingem mentplate plate. strip lining.

What code is often often used when constructing constructi ng vessels that operate operate at high high pressures? pressures? a) b) c) d)

13.

I nternally rnally braces Stiff Stiffe ening ring rings s Refractory Refractory lining Hemispherical rical heads

An opti optiona onallly part of an exchan exchange gerr that is used used to protect protect the tubes at the the inlet nozzle nozzle is called a(n): a) b) c) d)

12.

Resi esist erosion, erosion, insulate to reduceshel shell temperature perature Insulate nsulateto reduceshel shell temperature, perature, resist thermal expansi expansion Resist corrosion, resist thermal expansion Resi esist stress corrosi corrosion on cracking, cracking, insulate to reduce reduce shel shell temperature perature Beautify the facility, improve rate of heat transfer

an API 510 inspe nspector on staf staff. access to an AWS AW S insp i nspect ector. or. a written quality-control manual. a machine capable ble of making aking dishe dished d heads.

The vessel manufacturer manufacturer stamps the vessel with with the code symbol symbol “U”. “U ”. What is the meaning ning of a this this code code stamp? a) b) c) d) e)

All appl appliicabl cable requi requirements ents of the ASM SME E Code have have bee been met All requirements ents of the the U-Section in the ASM SME E Code have have bee been met Vessel essel has been hydrotested hydrotested Vessel essel has been radiographe radiographed Vessel wall is of uniform thickness

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September 2005

API 572 Study Guide Practice Questions 16.

A vessel should be maintained in accordancewith the: a) b) c) d)

construction code. latest edition of ASME Section VIII. code that was last used to rate the vessel. pre-2000 edition of ASME Section VIII.

17.

An inspector should befamiliar with any _____________________ that govern the inspection and maintenance of pressure vessels.

18.

List the 2 basic reasons for inspection of pressure vessels

19.

20.

1)

 ________________________________________________________________ 

2)

 ________________________________________________________________ 

List the 3 basic forms of deterioration 1)

 ______________________________________________ 

2)

 ______________________________________________ 

3)

 ______________________________________________ 

The corrosion rateresulting from corrosion-erosion is often: a) b) c) d)

21.

22.

List process conditions that that could changethe corrosion rate. 1)

 ______________________________________________ 

2)

 ______________________________________________ 

3)

 ______________________________________________ 

4)

 ______________________________________________ 

5)

 ______________________________________________ 

What metallurgies aremost affected by CUI? a) b) c) d)

23.

Carbon steel and low chromes Carbon steel and all chromes Carbon steel and stainless steels Carbon steel, chromes and stainless steels

List the temperature rangewhere CUI is most prevalent: 1) 2)

24.

higher than thecorrosion ratefrom corrosion without erosion. lower than thecorrosion ratefrom corrosion without erosion. higher in stagnant areas. uniform throughout the whole vessel.

Carbon Steels Stainless Steels

_________________ oF _________________ oF

Insulated carbon steel vessels may be subject to CUI if operating: a) b) c) d)

above the lower-transformation temperature. below the upper transformation. in an intermittent service. above 700oF.

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September 2005

API 572 Study Guide Practice Questions 25.

Which of thefollowing methods is NOT used to detect CUI? a) b) c) d) e)

26.

Which deterioration mechanismcan causedirection grooving? a) b) c) d)

27.

28.

29.

1)

______________________________________________ 

2)

______________________________________________ 

3)

______________________________________________ 

4)

______________________________________________ 

Match up the corrosion mechanismwith the applicable material. (SCC = stress corrosion cracking) A)

ChlorideSCC

_____ Alkaline systems

B)

Polythionic SCC

_____ Non-stress relieved carbon steel

C)

Caustic SCC

_____ Stainless steel

D)

Amine SCC

_____ Operating temperatures over 400oF

E)

Carbonate SCC

_____ Sensitized stainless steel

When checking for cracks, which of the following inspection techniques is useful only for surface or near-surface cracks? Acoustic emission Eddy current Radiography UT angle beam

What is a useful technique to use to evaluatethe vessel cladding from outside surfaceof the vessel? a) b) c) d)

31.

Erosion Oxidation Sulfidation Temper-embrittlement

List four common areas where corrosion-erosion can occur.

a) b) c) d) 30.

Weld quality RT Profile RT Guided-wave UT Electromagnetic methods Visual inspection after removal of insulation

Acoustic emission Eddy current Profile radiography UT thickness gauging

During an internal inspection, operating deposits are found in a specific section of the vessel. The inspector must: a) b) c) d)

have all deposits removed. determine the causeof the deposits. determine if corrosion is occurring under thedeposits. record the volume of the deposits.

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September 2005

API 572 Study Guide Practice Questions 32.

Which deterioration mechanismis caused by cyclic stresses? a) b) c) d)

33.

Which of the following vessels is most susceptible to fatigue? a) b) c) d)

34.

Acoustic emission Eddy current Guided waveUT MFL

Why is it difficult to find fatigue cracking? a) b) c) d)

39.

circumferential welds. dissimilar welds. stainless steel welds. chrome welds.

What NDE method checks for cracks by increasing the vessel pressure above its normal operating pressure? a) b) c) d)

38.

corrosion fatigue. mechanical fatigue. thermal fatigue. velocity fatigue.

A prime location for thermal fatigue is at: a) b) c) d)

37.

Low operating temperatures High operating temperatures High operating pressures Excess vibrations from mechanical equipment

Cracking occurring in deaerators is attributed to: a) b) c) d)

36.

Coke drum Crude column FCCU regenerator Hydrotreater reactor

What is a common cause for high-cycle fatigue? a) b) c) d)

35.

Creep Fatigue Graphitization Temper-embrittlement

Fatigues cracks are very tight It is very difficult to predict thelocation of fatigue cracking The growth rateof fatigue cracks is very slow It takes many cycles to initate the crack, but relatively few cycles to propagate the crack all the way through the vessel wall.

List the three primary factors of creep: 1)

__________________________ 

2)

__________________________ 

3)

__________________________ 

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September 2005

API 572 Study Guide Practice Questions 40.

Creep cracking begins to occur in 1-¼ chrome steels at temperatures above __________  oF.

41.

At high temperatures: a) b) c) d)

42.

Which of thefollowing can permeatesteel (migrate through the steel)? a) b) c) d)

43.

Atomic hydrogen Atomic hydrogen and molecular hydrogen Atomic hydrogen and atomic helium Molecular hydrogen and helium

Susceptibility to HTHA attack increases as: a) b) c) d)

44.

atomic hydrogen reacts to form water. atomic hydrogen reacts to form hydrocarbons. molecular hydrogen disassociates to form atomic hydrogen. molecular hydrogen disassociates to form water.

chromecontent increases. nickel content increases. metal grain size decreases. metal grain size increases.

Susceptibility to HTHA attack increases as: a) b) c) d)

operating temperature decreases. operating pressure decreases. carbon content increases. molybdenum content increases.

45.

HTHA can occur in 1-¼ chrome steels at temperatures above __________ oF.

46.

What publication provides safe operation limits for steels operating in hydrogen service? a) b) c) d) e)

ASME Section II ASME Section VIII API 579 API 941 API 2201

47.

High temperaturesulfidation can begin to occur at temperatures above __________ oF.

48.

High temperature sulfide attack usually appears as: a) b) c) d)

49.

cracks. localized thinned areas. pits. uniformcorrosion.

A partial buried vessel should be inspected for soil-to-air corrosion. To perform this inspection, the soil should beexcavated: a) b) c) d)

1 to 2 inches. 3 to 6 inches. 6 to 12 inches. 12 to 36 inches.

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September 2005

API 572 Study Guide Practice Questions 50.

Small living organisms are the causeof biological corrosion. There arevarious ways that these living organisms cause theactual corrosion to occur. Which of the following is NOT a way biological corrosion occurs? a) b) c) d)

51.

What is a common micro-organismin soils that can causebiological corrosion? a) b) c) d)

52.

54.

A)

Decarburization

_____ Selective leaching of a material in an alloy

B)

Graphitization

_____ Loss of carbon near surface of ferrous material

C)

Dealloying

_____ A metallurgical change that occurs to Cr-Mo alloys due to operating at high temperatures

D)

Temper Embrittlement

_____ Conversion of carbides to carbon nodules

What two factors cause decarburization in ferrous materials? Low operating temperatures, and numerous pressure cycles High operating temperature, and numerous pressure cycles Low operating temperatures, and a process that reacts with carbon High operating temperature, and a process that reacts with carbon

Which of the following is NOT a problemcaused by decarburization? a) b) c) d)

56.

improper heating and cooling. excessive thermal expansion. operating at cold temperatures. pressure cycles.

Match up the deterioration mechanismwith the applicable description.

a) b) c) d) 55.

amoebas chloride-reducing bacteria sulfate-reducing bacteria oxygen-reducing parasites

Changes in a metal’s microstructure can be caused by: a) b) c) d)

53.

Hydrogen normally slows down the corrosion rate on the external surface. Organisms consumes (reacts with) hydrogen. Since less hydrogen is now available, the corrosion rate to increase. Creates an electrolytic concentration cell Creates by-products that are corrosive Creates atomic nitrogen. A tomic nitrogen reacts with iron to form iron nitrate.

Material strength decreases Material toughness decreases Hardness of material increases Fatigue strength decreases

Decarburization is found using: a) b) c) d)

metallography. straight beamUT. penetrant testing. MFL.

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September 2005

API 572 Study Guide Practice Questions 57.

What materials are most susceptible to Graphitization? a) b) c) d) e)

58.

Graphitization occurs when a susceptible material is subject to: a) b) c) d)

59.

low temperatures. a prolonged exposure to temperatures above 750oF. a prolonged exposure to temperatures above 1100oF. atomic hydrogen.

Brittle fracture is usually not a concern when using: a) b) c) d)

64.

Carbon steel and carbon – ½molybdenum steel Carbon steel and low chromes (through 5% chrome) Low chromes All chromes Stainless steels

Temper embrittlement is caused when a susceptible material is subject to: a) b) c) d)

63.

Brass Bronze Monel Alloy 20

What materials are most susceptible to temper embrittlement? a) b) c) d) e)

62.

Localized graphitization Randomgraphitization Uniform graphitization Spot graphitization

In some water services, dezincification can occur in which materials? a) b) c) d)

61.

many temperature cycles. a prolonged exposure to temperatures above 450oF. a prolonged exposure to temperatures above 825oF. atomic hydrogen.

Which type of graphitization is most likely to lead to a mechanical failure? a) b) c) d)

60.

Carbon steel and carbon – ½molybdenum steel Carbon steel and low chromes (through 5% chrome) Carbon steel and all chromes High nickel alloys Stainless steels

carbon steels. low chromes. thin-wall materials. post-weld heat treat materials.

When do most brittle failures in pressure vessels occur? a) b) c) d)

During thevessel’s first winter weather During the first hydrotest After prolong exposure to temperatures above 250oF. After thefirst pressurecycle

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September 2005

API 572 Study Guide Practice Questions 65.

Brittle failures initiateat a notch or stress concentration. Most often, this the initiating point is a: a) b) c) d)

66.

Which of the following deterioration mechanisms can be corrected by annealing the steel? a) b) c) d)

67.

High residual stresses Increased density of material Hard zones in material Soft zones in materials Increased material strength Decreased material strength Increased susceptibility to cracking

When setting theinspection interval for theinternal inspection, an interval is selected so that at the next inspection: a) b) c) d)

71.

hydrogen. oxygen. nitrogen. zinc.

Which of the following is NOT a potential result of an improper heat treatment? a) b) c) d) e) f) g)

70.

visual inspection. eddy current examination. digital UT. angle beam UT.

Hydriding of titaniumalloys is caused when the material absorbs: a) b) c) d)

69.

Decarburization Dealloying Temper embrittlement HTHA

The most common method to check for freeze damageis by: a) b) c) d)

68.

tee joint or angle joint, e.g. nozzle-to-shell weld, tray ring weld. stamping in the vessel component. lamination in theplate. welding flaw.

the wall thickness is not less than the minimumrequired thickness. at least 0.100” of corrosion allowance remains. at least 25% of the current corrosion allowance should still remain. at least 50% of the current corrosion allowance should still remain.

One important factor in developing an inspection plan for the next inspection is to occasionally check the: a) b) c) d)

Operating department’s equipment records. Maintenancedepartment’s equipment records. Financial department’s equipment records. Environmental department’s equipment records.

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September 2005

API 572 Study Guide Practice Questions 72.

Before performing a vessel inspection, which of thefollowing activities does the inspector NOT need to do? a) b) c) d) e)

73.

A vessel has a refractory lining. During the internal inspection, an small area of damaged refractory is found. It is now important to: a) b) c) d)

74.

only with a visual examination. by visual examination and UT. by visual examination and RT. by visual examination and hammer-testing.

Small depressions on platforms are of concern since these can: a) b) c) d)

78.

Residual penetrant can causecrevice corrosion Residual penetrant can causesteel to become anodic Vapors from the examcan displace air It is more difficult to prepare the shell for the examas compared to other NDE methods

Ladders and platforms should be inspected: a) b) c) d)

77.

calibrated daily. calibrated weekly. rated for the appropriate gaseous atmosphere. certified by UL-142.

When performing a PT examination inside an exchanger shell, what is one potential problem? a) b) c) d)

76.

replace therefractory with superior materials. remove enough of the refractory to determine the condition of the basemetal. remove the damaged refractory plus 50% more to determine the basemetal condition. remove and replace all the refractory in the entire vessel.

All NDE tools should be: a) b) c) d)

75.

Review past inspection records. Check with Operations to determine whether there were any abnormal operating conditions. Review the equipment construction details. Review thevessel’s service conditions Determine what is being offered as the“daily special” at thelocal lunch café.

collect and hold water, potentially causing accelerated corrosion. createa tripping hazard. create flexing that could cause a fatigue failure. be rather ugly and prevent your facility from achieving API’s Petrochemical Facility of the  Year award.

Crevice corrosion is NOT common at which of the following locations? a) b) c) d)

Under nuts on anchor bolts At repad-to-shell welds Where handrail supports slip into platform sleeves Between exchanger shell and cradle support

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September 2005

API 572 Study Guide Practice Questions 79.

Which of thefollowing is usually NOT a cause of large cracks in a concrete foundations? a) b) c) d)

80.

Small hair-like cracks in concrete foundations: a) b) c) d)

81.

Visual examination UT Eddy current Hammer-testing with light taps Sledge hammer-testing with a 25 lb sledge hammer

What is one important itemto check during an External inspection of an exchanger? a) b) c) d)

86.

Painting Fireproofing Galvanizing Insulation

What is a good way to check for disbanded fireproofing? a) b) c) d) e)

85.

Visual UT Eddy current Hammer-testing Acid etching

What is the best way to prevent external corrosion on structural steel? a) b) c) d)

84.

serious foundation settlement. selecting the wrong material for the anchor bolt. using an anchor bolt of insufficient diameter. using an anchor bolt of insufficient length.

What examination method is normally used to examine in-service anchor bolts? a) b) c) d) e)

83.

should always be caulked. should always be repaired with a cement material similar to the original material. should be further examined by hammer-testing. are usually not a serious concern.

A distorted anchor bolt is usually the result of: a) b) c) d)

82.

High temperature. Excessive settlement. Poor design. Poor materials.

Surface temperature at the inlet and outlets The floating end of theexchanger is freeto slide on it’s support Determine the fluid flow rate through both the shell side and tube side of the exchanger Measure the clearance between the shell and the ground

Guy wires supporting tall vessels should be examined using: a) b) c) d)

visual examination. UT. profile RT. acoustic emission.

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September 2005

API 572 Study Guide Practice Questions 87.

Guy wire clips should be placed at a spacing of at least: a) b) c) d)

88.

Which of the following would be most affected if a vessel foundation experiences excessive settlement? a) b) c) d) e)

89.

3”. 6”. 3 guy wire diameters. 6 guy wire diameters.

Stiffener rings Relief devices Nozzles with attached piping Manways Top head

What should be doneif shell distortion is found at a nozzle? a) b) c) d)

Check for cracking on all nozzle welds Check the hardness of nozzle welds and nozzle components Check thickness by taking UT readings on a 2” grid on all nozzle components and on the distorted area of the shell. Only note the distortion in your inspection report

90.

Catalytic reformer vessels may have creep damageif the operating temperature is above _______  oF

91.

Thegrooves on an existing ring-joint flange should bechecked for ___________________.

92.

Grooves on existing stainless steel flanges should be checked for: a) b) c) d)

93.

Existing slip-on flanges should be checked for: a) b) c) d)

94.

chloride cracking. creep. crevice corrosion. graphitization.

Vessel grounding connections are primarily needed to provide a path for electrical current from: a) b) c) d)

95.

stress corrosion cracking. temper embrittlement. dealloying. corrosion fatigue.

a lighting strike or from a welding machine. a lighting strike or from static electricity. a welding machine or from an electrical short. an electrical short or from static electricity.

The maximumpermitted resistance-to-ground for a vessel grounding systemis: a) b) c) d) e)

0.5 ohms. 5.0 ohms. 10 ohms. 25 ohms. 50 ohms.

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September 2005

API 572 Study Guide Practice Questions 96.

Which of the following coating failures is easily missed during a visual examination? a) b) c)

97.

Where aretwo likely areas where paint failures occur? a) b) c) d) e)

98.

Film lifting Blisters Rust spots

Top heads and nozzles Weld seams and nozzles Top heads and moist crevices Weld seams and moist crevices Nozzles and moist crevices

What two on-stream NDE techniques may be able to locate moist insulation? a) b) c) d) e) f)

Real-time RT and Thermography Real-time RT and MFL Neutron back scatter and Thermography Neutron back scatter and MFL Neutron back scatter and Real-time RT  Thermography and MFL

99.

Pit depth is normally measured with a ________________________________.

100.

Theminimum number of TML’s required for a routine vessel is at least _______ thickness reading(s) on each shell ring, and _______ thickness reading(s) on each head.

101.

A vessel operates in a cyclic temperature service. The vessel support-to-vessel welds should be checked using MT or PT to check for: a) b) c) d)

stress corrosion cracking. fatigue cracking. polytheonic cracking. HTHA.

102. Which of thefollowing is NOT a significant factor in atmosphere corrosion? a) b) c) d)

vessel operating pressure relative humidity chemical vapors metal surface temperature

103. In a caustic storage vessel, caustic embrittlement is least likely at: a) b) c) d)

heating coil connections. areas of high stress. internal baffles or vortex breakers. nozzles.

104. Caustic that seeps through a crack will often leave a: a) b) c) d)

brown residue. white salt. yellow sticky deposit. black hard residue.

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September 2005

API 572 Study Guide Practice Questions 105.

A vessel contains an acid corrodent. The areas directly below theliquid level are likely to be subject to: a) b) c) d) e)

106.

hydrogen blistering. HTHA. temper embrittlement. graphitization. caustic cracking.

Blisters on a vessel shell can be easily detected with: a) b) c) d)

UT. RT. visual exam using a flashlight beam perpendicular to the shell. visual exam using a flashlight beam parallel to the shell.

107. Small blisters can be easily detected by: a) b) c) d)

feeling the surface with your fingers. hammer testing. MT or PT. magnetic flux leakage.

108. Why is wet fluorescent magnetic particle testing often used to detect certain types of cracking? a) b) c) d)

Easier to perform than other types of MT Requires less effort to qualify the NDE examiner as compared to dry MT More sensitive technique as compared to dry MT Equipment to perform the exam is less expensive than what is needed for other MT exams

109.  Tough question! The temperature of a hot-spot on a refractory lined vessel should be periodically checked. Which of thefollowing is NOT an acceptable method for checking the temperature? a) b) c) d) 110.

A hot-spot has developed on a refractory lined carbon steel vessel. During the next internal inspection the wall at the hot-spot should be metallurgically examined whenever the metal temperature has exceeded: a) b) c) d)

111.

Portable thermocouple  Thermography  Temperature indicating crayons. Place your hand on surface for exactly 1 second. Calculate the vessel temperature based on the depth of the 3rd degreeburns on your hand.

450oF. 750oF. 850oF. 1100 oF.

Normal vessel cleaning methods, like steam cleaning, usually are adequate to meet theinspector’s needs for an internal inspection. Extra cleaning such as abrasive-grit or water blasting may be required when inspecting for: a) b) c) d)

localized thin areas. deep pitting. stress corrosion cracking. thermal fatigue cracking.

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September 2005

API 572 Study Guide Practice Questions 112.

An internal inspection will beperformed on a vessel. What is the initial step to be performed? a) b) c) d)

Collect all necessary inspection tools Check the vessel permitting requirements Collect thenecessary personnel protective equipment Read the previous inspection reports

113. Sulfidation is a common concern at the: a) b) c) d)

top of the crude unit’s fractionating column. bottom of the crude unit’s fractionating column. top of a hydrotreater reactor. bottom of a hydrotreater reactor.

114. A vessel subject to wet hydrogen sulfide or cyanide environments is susceptible to. a) b) c) d)

cracks in the basemetal. cracks in the weld and heat affected zones. localized thin areas (LTA’s). extensive pitting.

115. If sludge settles on the bottomhead of a vessel, what corrosion mechanism is likely to occur? a) b) c) d)

Stress corrosion cracking Dealloying Concentration cell corrosion Sludgitization

116. If steamis injected into a vessel, a likely placefor corrosion is on the: a) b) c) d)

inlet nozzle. vessel wall opposite thenozzle. vessel wall directly below the nozzle. vessel’s anchor bolts. (once again proving it is difficult to come up with 3 wrong answers!)

117. When a reboiler is used with a tower (fractionating column), a common placefor corrosion is: a) b) c) d) 118.

the inlet to the reboiler. top head of the tower. at the tower where thehot process returns. at the tower where the cold process returns.

What is thenormal cause of corrosion associated with reboilers? a) b) c) d)

Hot process decomposes to form acids Hot process decomposes to form polytheonic caustic Increased velocity of returning process causes erosion Deposits in the process cause oxygen pitting

119. Most cracks that occur in a vessel occur at ______________________. 120. Exchangers in cooling water service havethe highest corrosion rates where the: a) b) c) d)

velocity is thehighest. velocity is the lowest. ph is the highest. water temperature is the highest.

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September 2005

API 572 Study Guide Practice Questions 121.

An impingement plateis installed on an exchanger bundle. What areais most susceptible to corrosion? a) b) c) d)

Exchanger shell near the impingement plate Tubesheet Tubes near the impingement plate Inlet nozzle

122. During an internal inspection: a) b) c) d) 123.

at least 10% of all welds should be checked with either MT or PT. 100% of the internal surface should becleaned. thickness readings should be taken at suspect locations. hammer-testing should be performed on all nozzles.

List 4 major areas where cracks occur in vessels madeof low chromes (i.e. 1-1/4 & 2-1/4 Cr). a)

 __________________________________________ 

b)

 __________________________________________ 

c)

 __________________________________________ 

d)

 __________________________________________ 

124. A very effective means to find cracks is by using: a) b) c) d)

MFL. red dye PT. dry particle MT. wet fluorescent particle MT.

125. Which of thefollowing steels is most likely to crack? a) b) c) d)

Steels with a tensile strength lower than 70,000 psi Steels with a yield strength above 20,000 psi. Coarse-grain steels Fine-grain steels

126. Normally tower (column) trays are inspected using: a) b) c) d) 127.

only a visual examination. visual examination and UT. visual examination and some type of crack detection NDE method. visual examination, UT and some type of crack detection NDE method.

Often corrosion will occur on the shell of an exchanger at the location of thebaffles. An easy way to find this corrosion is by: a) b) c) d)

spot UT. visual examination. eddy current testing. shining a flashlight beamparallel to the shell.

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September 2005

API 572 Study Guide Practice Questions 128.

Areas directly above theliquid level in vessels containing acidic corrodents s are subject to: a) b) c) d) e) f)

caustic embrittlement. hydrogen blistering. graphitization. creep. fatigue. dealloying.

129. How can small blisters easily be found? a) b) c) d) 130.

Existing exchanger shells sometimes become out of round making it difficult to reinsert the bundle. What is the most common causeof exchanger shell out-of-roundness? a) b) c) d) e) f)

131.

Feel metal surface with your fingers Visual examination Hammer-testing Spot UT readings

Over pressure Elevated temperature Metal fatigue Creep Welding repairs to theshell Meteor strike

Vessels containing amines are subject to: a) b) c) d) e)

oxygen pitting. oxidation. cracking. caustic embrittlement. dew point corrosion.

132. Deaerators used for boiler feedwater are subject to: a) b) c) d) e)

pitting. localized thinned areas. uniform corrosion. cracking. dealloying.

133. Loose or cracked metallic linings can be found using: a) b) c) d)

light taps with a hammer. visual inspection. MT. acoustic emission.

134. Bulged linings are often the indication of a _______________ in the liner. 135.

Whenever there are indications that a metallic liner has leaked, it is important to determine the: a) b) c) d)

thickness of theliner. displacement of the bulged area. condition of the basemetal under the liner. the identification of thewelder who previously installed theliner.

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API 572 Study Guide Practice Questions 136.

What type of weld metal overlay is often used for hydrotreater reactors? a) b) c) d) e)

137.

Low chromes High chromes Austenitic stainless steel Stabilized austenitic stainless steel High nickel alloys

What are thetwo primary purposes for refractory linings? 1)

____________________________________________ 

2)

____________________________________________ 

138. A break or void in a paint coating is called a: a) b) c) d) e)

blister. film lift off. holiday. voidea. lamination.

139. A common tool used to find breaks in a pipe coating is: a) b) c) d) 140.

Spark testing is being performed on a coating. What happens if the voltageon a spark tester exceeds the dielectric strength of the coating? a) b) c) d) e)

141.

acoustic emission. eddy current. MFL (magnetic flux leakage). spark testing.

Coating will become magnetic Strength of the coating bond increases A hole is “blown” in thecoating Coating will crack Creates a nuclear chain reaction that will destroy the entire universe

A common tool used to inspect refractory is a _________________________.

142. Extra metal thickness in a vessel is: a) b) c) d)

sometimes used as nozzle reinforcement. always considered extra corrosion allowance. always clearly identified on a U-1 form. never allowed.

143. When arefractory lining cracks, what is acommon problemthat occurs to thebase metal? a) b) c) d)

Dew point corrosion Dealloying Excessive thermal stress Brittle failure

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September 2005

API 572 Study Guide Practice Questions 144.

What method is often used to detect metallurgical changes to the base metal? a) b) c) d) e)

145.

Tension tests Bend tests Metallography Flash radiography Impact tests

What method is often used to detect carburization and decarburization? a) b) c) d) e)

Tension tests Bend tests Metallography Hardness testing Impact tests

146.

It is recommended NOT to hammer test vessels that are _________________________.

147.

Which of thefollowing is NOT a purpose of a pressure test? a) b) c) d)

148.

What is themost important concern when hydrotesting a large in-service vessel? a) b) c) d)

149.

vessels of simplistic design. vessels where internal inspections are difficult to perform. large vessels. heat exchangers.

A pneumatic pressure test is performed on alarge vessel. What is one way to determine the location of remote leaks? a) b) c) d)

151.

Rope off an area equal to 1000 sq. ft. for every 1’ of vessel height Provide multiple calibrated pressure gauges Assure the water used has less than 50 ppmof particulates Assure vessel foundation and supports are adequatefor the hydrotest weight

Acoustic emission testing is especially useful on: a) b) c) d)

150.

Validate vessel MDMT Assure equipment tightness Assure equipment integrity Redistributestresses at discontinuities

Block-in the vessel and seeif the pressure drops UT leak detector Binoculars Thermography

A vessel is being vacuumtested. What is one negative aspect of a vacuumtest? a) b) c) d)

Location of leak is not easily identified Thereare additional safety precautions as compared to a hydrotest Creating the vacuumrequires expensive equipment The vacuummust be held for 24 hours

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September 2005

API 572 Study Guide Practice Questions 152.

An in-service vessel has a shell thickness of 2.5”. The minimummetal temperatureallowed during a pressure test is: a) b) c) d) e)

153.

An in-service vessel has a shell thickness of 1.25”. The minimum metal temperature allowed during a pressure test is: a) b) c) d) e)

154.

Stationary tubesheet roll leaks Floating head tubesheet roll leaks Floating head gasket leak. Leaking tubes The exact location of any leak cannot be determined with this test

A tube-side pressure test is being performed on an exchanger with a floating head bundle. The bundle is in the shell and thepiping connected to a bottomshell nozzle is removed. This test will show overall bundle integrity and can be used to specifically locate which of the following leaks? a) b) c) d) e)

157.

ASME B&PV Section I ASME B&PV Section V ASME B&PV Section VII I ASME B31.3 API 579 API 2201

A shell-side pressure test is being performed on an exchanger with a floating head bundle. The bundle is in the shell and the channel cover is removed. This test will show overall bundle integrity and can be used to specifically locate which of the following leaks? a) b) c) d) e)

156.

10oF. 30oF. 60oF. 10oF. above the vessel MDMT. 30oF. above the vessel MDMT.

When performing a pneumatic pressure test, the requirements of which code should be followed? a) b) c) d) e) f)

155.

10oF. 30oF. 60oF. 10oF. above the vessel MDMT. 30oF. above the vessel MDMT.

Stationary tubesheet roll leaks Floating head tubesheet roll leaks Floating head gasket leak. Leaking tubes The exact location of any leak cannot be determined with this test

A tube-side pressure test is being performed on an exchanger with a floating head bundle. The bundle is outside theshell and a test head is bolted to the stationary tubesheet. This test will show overall bundle integrity and can be used to specifically locate which of the following leaks? a) b) c) d) e) f)

Stationary tubesheet roll leaks Floating head tubesheet roll leaks Floating head gasket leak. Leaking tubes Roll leaks on both ends, tube leaks, and floating head gasket leaks The exact location of any leak cannot be determined with this test

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September 2005

API 572 Study Guide Practice Questions 158.

During a bundle pressure test, a leaking tubeis discovered. The inspection results indicate that the other tubes are acceptable for a future operational run. The leaking tube is normally: a) b) c) d) e)

159.

During a bundle pressure test, a tuberoll-leak is discovered. The inspection results indicate that the other tubes are acceptable for a future operational run. The leaking tube is normally: a) b) c) d) e)

160.

in the design of vessel stiffening. in thedesign of nozzle reinforcement. to improvethejoint efficiency. to minimize the number of RT’s..

Which of the following components usually does NOT havea specified minimum thickness? a) b) c) d) e)

164.

connect a PRV to prevent excessive pressure. have multiple pressure gauges connected for the test. assure that all tubes have been seal-welded at the tubesheet. determine whether the tubesheet is thick enough for the pressure.

A shell has a minimumthickness of 0.352” and has acorrosion allowance of 0.125”. The total thickness needed is 0.477”, so the designer orders 0.500” plate. The extra 0.023” is usually consider extra corrosion, but often thedesigner uses the“extra” metal (and the extra is no longer extra): a) b) c) d)

163.

determine whether the tubes are thick enough for the external pressure. determine how far an areashould be roped off.. assure that all tubes have been seal-welded at the tubesheet. check the chloride content of the water.

Before applying a high-pressurehydrotest to abundle, it is important to: a) b) c) d)

162.

replaced in kind. replaced with improved metallurgy. plugged. removed. rerolled.

Before applying a hydrotest to theshell-side of a carbon steel bundle, it is important to: a) b) c) d)

161.

replaced in kind. replaced with improved metallurgy. plugged. removed. rerolled.

Top head Nozzle reinforcement Metallic liner Platform handrail Internal baffle

If a jurisdiction requires avessel repair to meet theNational Board Inspection Code, what stamp would have to beused by the Repair Organization? a) b) c) d) e)

A U UV R VR

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September 2005

API 572 Study Guide Practice Questions 165.

A corroded shell area that has an areaof 2.5 ft2 is built-up with weld metal. How should the repair area normally be inspected? a) b) c) d)

166.

When removing a crack in avessel using flame or arc gouging: a) b) c) d)

167.

care must be taken to prevent the crack from growing. thecraftsman must be qualified in accordancewith ASME B&PV Section IX. the base metal should only be a P1 or P-3 material. the crack length cannot be greater than allowed in API 579.

A crack in a vessel is removed. The groove: a) b) c) d) e)

168.

Visual examination Visual examination and either MT or PT Visual examination and spot UT Visual examination and eddy current

must always be filled with weld metal of the same metallurgy as the basemetal. should be filled with weld metal of a higher alloy than thebase metal. should be filled with weld metal of the same tensile strength as the basemetal. should be filled with weld metal of a higher tensile strength than the basemetal. can be left unfilled provided adequatewall thickness remains and edges are blended.

Stairway treads that have been worn smooth: a) b) c) d)

can be roughened by placing weld beads on the worn surface. should always be replaced. are acceptable provided the tread thickness is adequate. should be repaired with epoxy based materials.

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API 572 Study Guide Answers 1. 2. 3. 4. 5. 6. 7. 8.

9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21.

22. 23. 24. 25. 26. 27.

28.

29. 30. 31. 32. 33. 34.

b  jacketed c b 1& B 2& C 3& A a

35. 36. 37. 38. 39. 40. 41. 42. 43. 44. 45. 46. 47. 48. 49. 50. 51. 52. 53.

d a) clad - rolled b) clad - explosion bonded c) plates welded to shell d) weld overlay a b c b a c a c regulations 1. determine condition 2. determine rate of deterioration 1. Electrochemical 2. Chemical 3. Mechanical a 1. Temperature 2. Stress 3. Vibration 4. Impingment 5. High Velocity c 1. 25 - 250 2. 150 - 400 c a a 1. Downstream of control valves 2. Downstream of orifices 3. Downstream of pump discharge 4. Flow direction changes 1& E 2& D 3& A 4& C 5& B b d c b a d

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54. 55. 56. 57. 58. 59. 60. 61. 62. 63. 64. 65. 66. 67. 68. 69. 70. 71. 72. 73. 74. 75. 76. 77. 78. 79. 80. 81. 82. 83. 84. 23

a b a d 1. Time 2. Temperature 3. Stress 900oF c a d c 800oF d 450oF d c d c a 1& C 2& A 3& D 4& B d c a a c a a c b c b d c a a b d a e b c c d a b a d a d c d September 2005

API 572 Study Guide Answers 85. 86. 87. 88. 89. 90. 91. 92. 93. 94. 95. 96. 97. 98. 99. 100. 101. 102. 103. 104. 105. 106. 107. 108. 109. 110. 111. 112. 113. 114. 115. 116. 117. 118. 119. 120. 121. 122. 123.

124. 125. 126. 127. 128. 129. 130. 131. 132. 133. 134. 135. 136.

b a d c a 900oF cracks a c b d a d c pit gauge 1& 1 b a c b a d a c d b c d b b c b c a welds d a c a) Attachment welds b) Main weld seams c) Gasket grooves (ring joint flg) d) Nozzle attachment welds d c a d b a e c d a leak c d

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137. 138. 139. 140. 141. 142. 143. 144. 145. 146. 147. 148. 149. 150. 151. 152. 153. 154. 155. 156. 157. 158. 159. 160. 161. 162. 163. 164. 165. 166. 167. 168.

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1) erosion resistance 2) insulation c d c hammer a a c d pressurized a d b b a e d c a e e c e a d b c d b a e a

September 2005