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API-571 exam Format | API-571 Course Contents | API-571 Course Outline | API-571 exam Syllabus | API-571 exam Objectives

Exam Code: API-571

Exam Name: Corrosion and Materials Professional

Total number of questions: 110 questions

Scored questions: 100 (the remaining 10 are pre-test / unscored)

Exam duration / time allotted: 3.25 hours (3 hours 15 minutes)

Question format: Multiple-choice



1. Terms- Definitions- and Acronyms (5-10% of exam)

- Basic terminology related to corrosion- materials degradation- and inspection.

- Key acronyms from API RP 571- such as those for environmental cracking (e.g.- SCC for Stress Corrosion Cracking)- high-temperature degradation (e.g.- HTHA for High-Temperature Hydrogen Attack)- and inspection methods (e.g.- UT for Ultrasonic Testing).

- Expected knowledge: Define and differentiate terms like "creep-" "fatigue-" "embrittlement-" and "morphology" in the context of refinery equipment.



2. General Corrosion and Materials Knowledge (5-10% of exam)

- Overview of corrosion principles: Uniform corrosion- localized corrosion (pitting- crevice)- galvanic corrosion- and microbiologically influenced corrosion (MIC).

- Materials selection: Common alloys in refining (e.g.- carbon steels- low-alloy steels- stainless steels- duplex alloys- nickel-based alloys).

- Environmental factors: pH- temperature- pressure- and fluid chemistry influencing degradation.

- Inspection fundamentals: Non-destructive testing (NDT) techniques like visual inspection- radiography (RT)- magnetic particle testing (MT)- and dye penetrant testing (PT).



3. Damage Mechanisms (80-85% of exam)



- Name of the Mechanism: Standard nomenclature from API RP 571.

- Description of Damage: How the mechanism initiates and propagates.

- Affected Materials: Specific alloys or components vulnerable.

- Critical Factors: Environmental conditions (e.g.- temperature thresholds- chemical concentrations) that accelerate damage.

- Affected Units or Equipment: Common locations in refineries (e.g.- crude units- hydrocrackers- amine units).

- Appearance or Morphology of Damage: Visual- macroscopic- or microscopic indicators (e.g.- branched cracks- grooving).

- Prevention/Mitigation: Design- material substitution- inhibitors- or operational controls.

- Inspection and Monitoring: Recommended NDT methods- monitoring intervals- and fitness-for-service exams (per API 579).



A. General Material Degradation (Mechanical and Thermal)

- Mechanical fatigue: Cyclic loading causing crack initiation.

- Thermal fatigue: Temperature fluctuations leading to cracking.

- Creep and stress rupture: High-temperature deformation under load.

- Brittle fracture: Low-temperature- high-stress failure.

- Erosion (e.g.- solid particle- liquid impingement): Material loss from flow.

- Vibration-induced fatigue: Equipment resonance issues.

- Spheroidization: Loss of strength in overheated steels.

- Temper embrittlement: Silicon/manganese effects in low-alloy steels.



B. Corrosion-Focused Mechanisms

- Uniform corrosion: General thinning (e.g.- CO2 corrosion in wet environments).

- Galvanic corrosion: Dissimilar metal couples.

- Atmospheric corrosion: External surface rusting.

- Microbiologically influenced corrosion (MIC): Bacterial activity in biofilms.

- Sour water corrosion (SWC): H2S in wet acidic conditions.

- Amine corrosion: Degradation in gas treating units.

- CO2 corrosion (sweet corrosion): Carbonic acid effects in pipelines.

- Hydrochloric acid (HCl) corrosion: From salt in crude.

- Sulfuric acid corrosion: Battery limits in alkylation units.

- Caustic corrosion: Embrittlement in pH>12 environments.

- High-temperature sulfidic corrosion (HTSC): FeS scale formation.

- Carburization and metal dusting: Carbon ingress at high temperatures.

- Oxidation: Scale formation on metals.

- Flue gas dew point corrosion: Sulfuric acid in stacks.



C. Environmental and Stress Cracking

- Stress-oriented hydrogen-induced cracking (SOHIC): Lined-up cracks in wet H2S.

- Hydrogen blistering: Gas pressure buildup.

- Stress corrosion cracking (SCC): Caustic- chloride- polythionic- or alkaline variants.

- Hydrogen stress cracking (HSC): HF acid in alkylation.

- Sulfide stress cracking (SSC): Wet H2S on hardenable steels.

- Amine stress corrosion cracking (ACC): CO2-loaded amines.

- Wet H2S environmental cracking: NACE MR0175 compliance.



D. High-Temperature Degradation

- High-temperature hydrogen attack (HTHA): Methane formation in steels.

- High-temperature oxidation: Alloy-specific scaling.

- Nitriding: Nitrogen absorption in ammonia services.

- Graphitization: Carbon segregation in cast irons.

- Short-term elevated temperature exposure: Temporary property loss.



E. Other Specialized Mechanisms

- Dissimilar weld metal cracking: Chromium carbide issues.

- Reheat cracking: Weld heat-affected zone failures.

- Delayed coking unit (DCU) decoke damage: Coke buildup erosion.

- Liquid metal embrittlement (LME): Mercury or lead effects.

- Corrosion fatigue: Combined cyclic stress and corrosive environment.

- Selective leaching (dealloying): Dezincification in brasses.

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