Pass the API ICP Programs API-571 Questions and answers with CertsForce

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.

According to API RP 941, and also noted in RP 571:

“Nickel significantly improves resistance to HTHA (High Temperature Hydrogen Attack) by stabilizing austenitic phases and reducing carbide decomposition.”

Hence, option C is correct.

API RP 571 emphasizes under Hydrogen Stress Cracking – Hydrofluoric Acid (HF):

“Cracking in carbon steel is influenced by high hardness and tensile stress in the presence of wet HF acid.”

“Controlling weld and heat-affected zone hardness to below 200 BHN is a key mitigation measure, as higher hardness significantly increases susceptibility.”

Steel hardness and strength are thus critical for cracking in HF environments, making option C correct.

According to API RP 571, under the section on High Temperature Hydrogen Attack (HTHA) and Decarburization:

“Decarburization is typically confirmed by metallographic examination. This method reveals carbon loss and microstructural changes such as spheroidization or softening of pearlite.”

“Tensile or impact testing may not reveal early-stage decarburization, especially in partial layers.”

Therefore, metallographic testing is the standard and most direct method to confirm decarburization damage, making option D correct.

Chloride Stress Corrosion Cracking (Cl-SCC) is a serious form of corrosion primarily affecting austenitic stainless steels and some duplex stainless steels, particularly when exposed to chloride-containing environments at elevated temperatures.

According to API RP 571 Section 5.1.2.3 (Chloride Stress Corrosion Cracking – Cl-SCC):

“Austenitic stainless steels (e.g., 300 series such as Types 304 and 316) are the most susceptible to Cl-SCC... Duplex stainless steels have greater resistance but are not immune, especially at temperatures >150°F (65°C)... Ferritic stainless steels (400 series) are generally not susceptible.”

Thus, Option A (400 Series Stainless Steel) is not susceptible to chloride SCC, making it the correct answer.

According to API RP 571 and API RP 751 (HF Alkylation Units):

“HF acid corrosion rates increase with elevated temperature and higher water content. This is because water acts as an ionizing agent that facilitates the acid’s attack on steel.”

“Corrosion is minimized when water content is strictly controlled, usually between 0.5–1.5%.”

“Contrary to some assumptions, increasing HF acid concentration actually decreases corrosivity.”

Hence, option B is correct.

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.

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.

API RP 578 (Material Verification Program), referenced in API RP 571, specifically calls out sulfidation failures as a major driver for Positive Material Identification (PMI):

“PMI programs are particularly important in services prone to sulfidation where incorrect alloying elements (e.g., carbon steel used in place of low Cr alloy) have led to catastrophic failures.”

“Many failures have occurred when carbon steel was mistakenly installed in place of specified Cr-alloys in sulfidation-prone environments.”

(Reference: API RP 578 and API RP 571, Section 4.2.1.1 – Sulfidation)

Thus, option C is the most appropriate answer.

Galvanic corrosion occurs when two dissimilar metals are electrically connected in the presence of an electrolyte such as brackish water or seawater. The rate and severity of galvanic corrosion depend on:

The relative position of the metals on the galvanic series (potential difference)

Area ratio between anode and cathode

Conductivity of the electrolyte

API RP 571 explains:

“The more active (anodic) metal in the galvanic couple corrodes preferentially. The more noble (cathodic) metal is protected.”

“The greater the difference in potential between the two metals, the more aggressive the galvanic reaction.”

“Aluminum is highly anodic compared to steel. In seawater or brackish conditions, aluminum will corrode rapidly when electrically coupled to steel, especially if the aluminum surface area is small relative to the steel.”

(Reference: API RP 571, Section 4.3.5.1 – Galvanic Corrosion)

Referring to the galvanic series presented in your table:

Aluminum is much higher (more anodic) than steel.

This makes aluminum the sacrificial metal in such a pair.

This is not the case for brass-to-nickel or cast iron-to-Ni-Resist, which are much closer together on the galvanic scale.

Therefore, among all the listed pairs, Aluminum coupled to Steel creates the most significant galvanic potential difference and is most likely to result in galvanic corrosion in brackish or seawater service.

Correct Answer: B