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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.