Refining Corrosion Technologist Practice Exam

Refining Corrosion Technologist Practice Exam

Chapter 1: Fundamentals of Refinery Corrosion

1.1 Introduction to Refinery Corrosion Mechanisms
1.2 Electrochemical Principles of Corrosion
1.3 Corrosion Cells and Reactions
1.4 Corrosion Risk Factors in Refineries
1.5 Damage Mechanism Classification
1.6 Corrosion Terminology and Definitions
1.7 Refinery Process Environments
1.8 Asset Integrity Fundamentals
1.9 Corrosion Management Strategies
1.10 Role of the Refining Corrosion Technologist

Chapter 2: High-Temperature Corrosion Mechanisms

2.1 Fundamentals of Sulfidation Corrosion
2.2 High-Temperature Oxidation
2.3 Metal Dusting Mechanisms
2.4 Carburization and Decarburization
2.5 Hydrogen Attack Fundamentals
2.6 Effects of Temperature on Corrosion Rates
2.7 Chromium's Role in Corrosion Resistance
2.8 Furnace and Heater Tube Damage
2.9 Material Selection for High Temperatures
2.10 High-Temperature Corrosion Case Studies

Chapter 3: Naphthenic Acid Corrosion (NAC)

3.1 Introduction to Naphthenic Acid Corrosion
3.2 Total Acid Number (TAN) Fundamentals
3.3 Temperature Effects on NAC
3.4 Velocity and Shear Stress Influence
3.5 NAC Damage Locations in Refineries
3.6 Interaction Between NAC and Sulfidation
3.7 Inspection Techniques for NAC
3.8 Mitigation and Control Strategies
3.9 Material Selection for NAC Service
3.10 NAC Failure Analysis Examples

Chapter 4: Overhead System Corrosion

4.1 Crude Unit Overhead Corrosion Fundamentals
4.2 Ammonium Chloride Corrosion Mechanisms
4.3 Salt Dew Point Concepts
4.4 Water Wash System Design
4.5 pH Control and Neutralization Programs
4.6 Under-Deposit Corrosion Processes
4.7 Chloride Monitoring and Control
4.8 Inspection and Monitoring Techniques
4.9 Overhead Corrosion Mitigation Methods
4.10 Overhead System Case Studies

Chapter 5: Sour Service and Hydrogen Damage

5.1 Hydrogen Sulfide Corrosion Mechanisms
5.2 Sulfide Stress Cracking (SSC)
5.3 Hydrogen-Induced Cracking (HIC)
5.4 Stepwise Cracking and Blistering
5.5 Wet H₂S Corrosion Environments
5.6 Material Hardness Requirements
5.7 Sour Service Material Selection
5.8 Hydrogen Damage Inspection Methods
5.9 Sour Water Corrosion Control
5.10 Hydrogen Damage Failure Analysis

Chapter 6: Amine, Sour Water, and REAC Corrosion

6.1 Amine System Corrosion Fundamentals
6.2 Heat-Stable Salt Effects
6.3 Erosion-Corrosion in Amine Systems
6.4 Sour Water Stripper Corrosion
6.5 Ammonium Bisulfide Corrosion
6.6 Reactor Effluent Air Cooler (REAC) Damage
6.7 Velocity Effects on Corrosion
6.8 Corrosion Monitoring Programs
6.9 Mitigation and Chemical Treatment
6.10 Inspection and Reliability Strategies

Chapter 7: Atmospheric Corrosion, CUI, and MIC

7.1 Atmospheric Corrosion Mechanisms
7.2 Corrosion Under Insulation (CUI) Fundamentals
7.3 CUI Temperature Ranges and Risks
7.4 Chloride Effects in CUI Environments
7.5 Corrosion Under Refractory (CUR)
7.6 Microbiologically Influenced Corrosion (MIC)
7.7 Biofilm Formation and Corrosion
7.8 Cooling Water System Corrosion
7.9 Inspection Techniques for Hidden Corrosion
7.10 Prevention and Mitigation Strategies

Chapter 8: Materials Selection and Corrosion Control

8.1 Carbon Steel Applications and Limitations
8.2 Low-Alloy Steel Performance
8.3 Stainless Steel Corrosion Resistance
8.4 Nickel-Based Alloy Applications
8.5 Material Selection Methodology
8.6 Corrosion Allowance Principles
8.7 Protective Coatings and Linings
8.8 Corrosion Inhibitor Programs
8.9 Reliability-Centered Material Selection
8.10 Case Studies in Metallurgical Upgrades

Chapter 9: Inspection, Monitoring, and Risk-Based Integrity

9.1 Corrosion Monitoring Fundamentals
9.2 Ultrasonic Thickness Measurements
9.3 UT Grid Mapping Techniques
9.4 Radiographic Inspection Methods
9.5 Online Corrosion Monitoring Systems
9.6 Fitness-for-Service Evaluations
9.7 Risk-Based Inspection (RBI) Principles
9.8 Damage Mechanism Reviews (DMR)
9.9 Integrity Assessment Methodologies
9.10 Inspection Planning and Documentation

Chapter 10: Refining Corrosion Technologist Exam Preparation

10.1 Certification Exam Structure and Objectives
10.2 High-Temperature Corrosion Review
10.3 NAC and Overhead Corrosion Review
10.4 Sour Service and Hydrogen Damage Questions
10.5 Amine and REAC Corrosion Scenarios
10.6 CUI and MIC Assessment Exercises
10.7 Materials Selection Practice Problems
10.8 RBI and Integrity Management Questions
10.9 Full-Length Mock Practice Exams
10.10 Final Review and Certification Readiness Assessment