Refining Corrosion Technologist NACE-RCT-001 NACE Cathodic Protection Technologist (CP3) Written Exam Exam Preparation Guide March 2018 Copyright 2016 by NACE International Institute. All rights reserved. Exam Preparation Guide May 2017 1
Table of Contents Introduction... 3 Target Audience... 3 Requirements... 4 Exam Blue Print... 5 Types of Questions... 8 Description of Questions... 8 Sample Questions... 8 Answer Key...10 Preparation...10 Training...10 Suggested Study Material...10 Books...10 Papers...10 Standards...10 Other...11 Calculators...12 Exam Preparation Guide Mar 2018 2
Introduction The Cathodic Protection Technologist (CP3) written exam is designed to assess whether a candidate has the requisite knowledge and skills that a minimally qualified Cathodic Protection Technologist (CP 3) must possess. The exam consists of 70 multiple-choice questions that are based on the Cathodic Protection body of knowledge. A candidate should have theoretical concepts and practical application of cathodic protection (CP) with a strong focus on CP field work, interpretation of CP data and troubleshooting. Test Name NACE- Cathodic Protection Technologist (CP 3) Written Exam Test Code Time 4 hours* Number of Questions 70 Format Computer Based Testing (CBT) NOTE: A pass/fail grade is provided at the end of the exam. The CBT exam and the essay exam are scored separately and candidates must pass both exams. *Exam time includes 4 minutes for the non-disclosure agreement and 6 minutes for the system tutorial. NOTE: The course manual is provided in the exam as a pdf. This pdf is intended to be reference material on questions that require a formula, conversion chart or other reference to answer specific questions. However, you must prepare for the exam as the exam was designed so that there is NOT enough time to look up the answer to every question. It is suggested that you limit your use of the reference material to approximately 20% of the exam. Target Audience Cathodic Protection Technologist (CP 3) is responsible for observing, recording, and measuring the effectiveness of Cathodic Protection (CP) systems. This certification is geared towards persons who have a high level of working knowledge of CP systems and years of extensive field experience in CP. CP Technologist should have good understanding of mathematical procedures and scientific knowledge of corrosion processes. NOTE: There is NOT a direct progression from Cathodic Protection Technician (CP 2) to Cathodic Protection Technologist (CP 3). Substantial experience involving all aspects of cathodic protection, including design and formal education in math/science/engineering is critical to student s success on this exam. Attendance in the Cathodic Protection Technician (CP 2) course is strongly recommended before attempting Cathodic Protection Technologist (CP 3). However, additional experience and education are also recommended. Exam Preparation Guide Mar 2018 3
Requirements Cathodic Protection Technologist (CP3) Requirements for Cathodic Protection Technologist (CP3): 1 Prerequisite Work Experience 2 Core exams Application The following prerequisite is required None Work Experience Requirements Choose one of the following work experience options: 8 years verifiable CP work experience 6 years verifiable CP work experience and 2 year post high school training from approved math / science technical / trade school 3 years verifiable CP work experience and 4 year physical science or engineering degree Core Exam Requirements The following exams are required: (2 core exams required) Cathodic Protection Technologist (CP 3) closed book exam (multiple choice, with relevant references) Cathodic Protection Technologist (CP 3) exam (essay / formula) NACE- CP3-001 Application Requirements Approved Cathodic Protection Technologist (CP3) application Note: Completion of course does not entitle the candidate to the certification. Submit Application - candidates must apply for this certification by submitting an on-line application which is subject to approval. Certification renewal requirements Recertification application* required every 3 years including the following A minimum of 1.5 years of cathodic protection work experience A completed re-certification Application A minimum of 24 Professional Development hours Upon successful completion of requirements, the candidate will be awarded a Cathodic Protection Technologist (CP 3) Certification *Approval required Next Level of Certification: Cathodic Protection Specialist (CP4) Exam Preparation Guide Mar 2018 4
Exam Blue Print NOTE: At the end of the CBT exam the candidate will receive a bar chart of strengths and weaknesses that correspond to these Domains. Domain 1- Basics - 1-3% Understand the relationship between voltage, current and resistance as expressed by Ohm s Law. Understand basic AC and DC circuits, to include series, parallel and series-parallel. Kirchoff s electrical circuit laws Understand the composition of a basic galvanic cell and the electro-chemical reactions that allow corrosion to occur at the anode rather than the cathode Understand the cause and effect of polarization in a galvanic cell Understand the concept cathodic protection and the two primary methods of applying it to metal objects underground or otherwise immersed in an electrolyte. Understand how corrosion cells are formed on Domain 2 - Instruments - 1-2% Understand the operation of a digital Volt-Ohm meter (Multimeter) and how it is used to measure current, voltage and resistance. Use a volt-ohm meter (Multimeter) to determine the voltage and current output of a rectifier. Understand the operation of a soil resistivity meter. Use a volt-ohm meter to determine the current output of sacrificial anodes installed on your system. Conduct a soil resistivity test with a soil resistivity meter or equivalent instrument. Conduct soil resistivity measurements by using a Domain 3 - Shunts - 1-2% Understand how to determine the amount of current flowing through various size shunts by reading the milli-volt (mv) drop across it with a Volt-Ohm meter and applying the correct conversion factor. metal objects that are underground or otherwise immersed in an electrolyte. Understand the physical and chemical characteristics of metals and electrolyte at affect corrosion rate Understand the forms of corrosion Understand the concept of shielding and how it can affect metallic objects that are cathodically protected. Understand the use of Faraday s first law in relation to cathodic protection and corrosion of metals Understand the Criteria for Cathodic Protection and its application Understand the other Non-NACE Standard related Criteria Soil Box. Understand and able to perform layer resistivity calculations Conduct single-point soil resistivity readings with a Collins Rod Install interrupters in rectifiers or bonds for the purpose of taking On and Instant off structure to electrolyte potential readings Understand the various types of pipe locating instruments and be able to utilize them to locate pipelines or cables in all underground environments. Understand how to determine the direction of current flow through a shunt by observing the polarity of the mv reading. Read shunts in rectifiers to determine the output current. Exam Preparation Guide Mar 2018 5
Read shunts in bonds with foreign structures. Read shunts for individual anodes associated with deep well ground beds. Utilize an external shunt to determine the Domain 4 - Periodic Surveys - 1-2% Conduct annual structure to electrolyte surveys on all facilities. Conduct rectifier readings. Conduct surveys of bonds. Conduct surveys of diodes or current reversing switches. Conduct soil resistivity surveys. Collect data on external coupon test stations. Conduct offshore platform and riser surveys Domain 5 - Reference Cells - 4-6% Understand the construction and operation of reference cells and maintain them in a manner that will provide comparative readings. Install permanent (stationary) reference cells and check them periodically to insure that are in good working order. Abide by the recommendations in the MSDS output current of a rectifier with a broken amp meter. Read shunts that are installed in galvanic anodes to determine output current Conduct 2wire / 4 wire line current test and correlate with the related coating resistance calculations Conduct Direct Current Voltage Gradient (DCVG) survey Conduct Close Interval Potential Survey (CIPS) or Pearson Survey Ability of identify any anomalies during the course of the survey being performed sheet pertaining to the handling and disposal of Copper Sulfate. Use and understand the different types of reference cells and the related conversions Use an antimony half-cell in comparison to a copper/copper sulfate half-cell for determining the ph of soils. Domain 6 - Field Tests - 3-5% Perform current requirement test. Perform soil ph test. Perform IR Drop test. Run shorted casing test on casings that are suspected of being shorted and interpret the results of the test. Perform coating examinations on sections of pipeline that have been excavated. Perform soil resistivity test to evaluate the area for a conventional ground bed site. Conduct Pearson surveys to evaluate the coating condition of a section of pipeline. Conduct computerized close interval surveys where needed and evaluate the graphs produced from the data. Locate breaks in header cables with a audio type pipe and cable locator Investigate shorts on a pipeline or other structure Verify the results of shorted casing test Understand the factors that affect cathodic protection system performance at the anode, at the structure performance, in the electrolyte, in the metallic path, at the power supply, because of anode arrangement and interference. Perform advanced cathodic protection testing using correct measurement techniques to monitor CP system performance and accurately interpret the data collected to ensure optimum cp system performance. Based on data collected, determine if correction/modifications to system components are necessary. Identify errors in data collection/cp measurements including contact resistance errors, voltage drop errors and, reference electrode errors, Utilize the instruments required to accomplish advanced cathodic protection testing and Exam Preparation Guide Mar 2018 6
collection of cathodic protection systems measurements. Conduct cathodic protection surveys including close interval surveys and DCVG where needed or required and evaluate the graphs produced from the data collected during the surveys. Troubleshoot rectifiers and make corrections/ Domain 7 - DC Stray Current Interference - 4-6% Conduct and document interference test where stray currents are suspected. Once interference test have been run, suggest method of control that will mitigate the effects of the stray current. Understand how IR Drop test stations can be used to evaluate stray current. Understand how Coupon Test station can be used to determine the presence of and the Domain 8 - AC Mitigation - 4-6% Understand the safety requirements when installing test stations under high voltage power lines Domain 9 - Corrosion Theory - 7-9% Understand the composition of a basic galvanic cell and the electrochemical reactions that allow corrosion to occur at the anode rather than the cathode. Describe the characteristics of anodic and cathodic reactions. Understand and apply the principles of electricity and electrical circuits (series, parallel, and series-parallel circuits) (including the application of Ohm s and Kirchhoff s Laws to electrical circuits.) Domain 10 - Polarization - 7-9% Understand the cause and effect of polarization in a galvanic cell Understand activation, concentration and resistance polarization and the mathematical Domain 11 - Cathodic Protection - 12-14% Understand the concept cathodic protection and be knowledgeable of the Components required for both galvanic and repair as necessary. Perform efficiency test on rectifiers. Install new rectifiers. Understand the use of external CP coupons and be able to identify if the use of external coupons is needed for a CP system. Understand in-line and direct inspection (understand and be able to implement ECDA) mitigation of stray current. Calculate the resistance required for to provide the amount of current drain desired at a resistance bond installation Understand the causes (sources) and the effects of interference. Understand the methods available to mitigate interference. Take appropriate steps to mitigate the effects of excessive AC voltage induced on underground structures Perform calculations using Ohm s Law and calculations related to series and parallel circuits. Understand how corrosion cells are formed on metal objects that are underground or otherwise immersed in an electrolyte. Understand Faraday s Law and perform calculations using Faradays law to determine required anode weight for cathodic protection. expressions of these concepts. Understand the factors that affect polarization (area, temperature, relative movement, ion concentration, oxygen concentration) impressed current systems. Be able to design and install simplistic forms of galvanic and impressed current cathodic Exam Preparation Guide Mar 2018 7
protection facilities. Understand the relationship between cathodic protection and other methods of corrosion mitigation Understand the factors that affect the amount of current required for a cathodic protection system. Understand the NACE criteria for Cathodic Protection and be able to apply the criteria and make adjustments as necessary to CP systems in order to comply with the criteria defined by the company where the technologist is employed. Understand IR drop and be able to determine Domain 12 - Corrosion Analysis - 2-4% Be prepared to provide an evaluation on the remaining wall strength where corrosion is found and make recommendations concerning the need for sleeves, reduction of Domain 13 - Design - 9-11% Utilize field data to accomplish the calculations required to design cathodic protection current sources. Select site locations and implement the design of cathodic protection current sources for distribution or transmission pipeline systems Design cathodic protection systems for the inside of water tanks the IR drop and apply correction techniques as needed. Understand and apply E Log I criteria and construct polarization curves. Understand the concept of current distribution and be able to determine ideal current distribution for a CP system taking into account the factors affecting current distribution (anode-to-cathode separation distance, electrolyte and structure resistivity variation, current attenuation). Understand the effects of current path geometry, protective coatings and polarization on current distribution MAOP or pipe replacement. Determine if corroded areas are active or passive corrosion. Discuss guidelines Design cathodic protection for the tank bottoms of aboveground storage tanks. Design cathodic protection for underground storage tanks Work with engineering in the proper use of insulation for newly designed facilities. Provide information on underground coating performance for those selecting coatings for new facilities Types of Questions Description of Questions The questions on this exam are multiple-choice where there is only one correct answer. The questions are based on the knowledge and skills required in the cathodic protection industry for a Cathodic Protection Technologist. While the NACE training course is an excellent method of preparation, it is not the only reference used in the development of the questions. Sample Questions The sample questions are included to illustrate the formats and types of questions that will be on the exam. Your performance on the sample questions should not be viewed as a predictor of your performance on the actual test. 1. If the potential of -700 mvcse is measured with the reference at 250C, what is the measured potential if the reference is at 400C? Exam Preparation Guide Mar 2018 8
A. -686 mvcse B. -700 mvcse C. -714mVCSE D. -868 mvcse 2. Which of the following conditions will increase galvanic anode polarization? I. increased agitation II. decreased Mn+ ions III. decreased temperature IV. decreases surface area A. I only B. I & II only C. III & IV only D. I, II, III & IV 3. How long during this 30 day period has the rectifier been OFF given the following data? DC output 15 Vdc and 10Adc 4 rev per minute on a KWH meter where K = 1 AC power consumption for the 30 day period is 120 KWH A. 0 days B. 9 days C. 12 days D. 21 days 4. Which one of the following would result in the largest corrosion rate according to Faraday s Law? A. A discharge current density of 10mA/ft 2 from a steel plate B. A discharge current density of 6µA/cm 2 from a lead plate C. A discharge current density of 100 ma/m 2 from a zinc anode D. A discharge current density of 10µA/cm 2 from an aluminum anode Exam Preparation Guide Mar 2018 9
Answer Key 1. C Reference: NACE Cathodic Protection Technologist level 3 Course Material 2. C Reference: NACE Cathodic Protection Technologist level 3 Course Material 3. B Reference: NACE Cathodic Protection Technologist level 3 Course Material 4. B Reference: NACE Cathodic Protection Technologist level 3 Course Material Preparation Training NACE Cathodic Protection Technologist (CP 3)- Course Strongly Recommended Prerequisite Training NACE Cathodic Protection Technician CP2 - Course NACE Cathodic Protection Tester (CP1)- Course Suggested Study Material NACE Cathodic Protection Technologist (CP 3) - course material NACE Cathodic Protection Technician (CP2) - course materials NACE Cathodic Protection Tester (CP1) - Course materials Books Holtsbaum, W. B. (2012). Cathodic protection survey procedures. NACE International, the Corrosion Society. Papers Ansuini, Frank J., James R. Dimond, Factors Affecting the Accuracy of Reference Electrodes, Materials Performance, 33, 11 (1994): pp. 14-17. Standards Latest editions should be used for all standards. Certain content from these standards are incorporated in the NACE Cathodic Protection Technician (CP 2) course materials and some of them are included in the course manual SP0169 SP0285 Control of External Corrosion on Underground or Submerged Metallic Piping Systems Corrosion Control of Underground Storage Tank Systems by Cathodic Protection Exam Preparation Guide Mar 2018 10
SP0388 SP0177 SP0575 SP0176 RP0193 SP0196 SP0290 SP0200 TM0497 TM0101 Other Impressed Current Cathodic Protection of Internal Submerged Surfaces of Carbon Steel Water Storage Tanks Mitigation of Alternating Current and Lightning Effects on Metallic Structures and Corrosion Control Systems Internal Cathodic Protection (CP) Systems in Oil-Treating Vessels Corrosion Control of Submerged Areas of Permanently Installed Steel Offshore Structures Associated with Petroleum Production External Cathodic Protection of On-Grade Carbon Steel Storage Tank Bottoms Galvanic Anode Cathodic Protection of Internal Submerged Surfaces of Steel Water Storage Tanks Impressed Current Cathodic Protection of Reinforcing Steel in Atmospherically Exposed Concrete Structures Steel-Cased Pipeline Practices Measurement Techniques Related to Criteria for Cathodic Protection on Underground or Submerged Metallic Piping Systems Measurement Techniques Related to Criteria for Cathodic Protection of Underground Storage Tank Systems American Water Works Association (AWWA) Standard D104 Automatically Controlled, Impressed Current Cathodic Protection for the Interior of Steel Water Tanks. American Petroleum Institute (API) Recommended Practice 651, Cathodic Protection of Above Ground Petroleum Storage Tanks. Recommended Practice 1632, Cathodic Protection of Underground Petroleum Storage Tanks and Piping Systems. U.S. Government, Code of Federal Regulations (CFR) 49CFR Part 192, Subpart I Natural Gas Pipelines 49CFR Part 193, Subpart G Liquefied Natural Gas 49CFR Part 195, Subpart D Hazardous Liquid Pipelines 40CFR Part 280 Underground Storage Tanks Exam Preparation Guide Mar 2018 11
Calculators Students will have access to either a TI Standard or TI Scientific calculator for use during the CBT Exam. Standard Calculator Scientific Calculator Standard Mode Functions Add + Subtract - Multiply x Divide Negative (-) Percentage % Square Root Example: 4 Reciprocal (Inverse) x Example: 1 2 = Store value to variable M+ Example: 3 * 5 = M+ Access variable MRC Example: 7 + MRC = Clear variable M- MRC Scientific Mode Functions Add + Subtract - Multiply x Divide Negative (-) Percentage 2nd [%] Square Root Example: 2nd 4 enter Reciprocal (Inverse) X -1 Example: 2 X -1 enter Store value to variable sto X yzt Example: 3 * 5 enter sto X yzt enter Access variable X yzt or Example: 7 + 2nd [recall] enter enter 2nd [recall] s s Numeric Notation Standard (Floating Decimal) Notation (digits to the left and right of decimal Scientific Notation (1 digit to the left of decimal and appropriate power of 10) Engineering Notation (numer from 1 to 999 times 10 to an integer power that is a multiple of 3) mode menu options NORM SCI ENG e.g. 123456.78 FLOAT 0 1 2 3 4 5 e.g. 123456.7800 mode menu options NORM SCI ENG e.g. 1.2345678*105 mode menu options NORM SCI ENG e.g. 123.45678*103 Exam Preparation Guide Mar 2018 12
ss ss Fractions Simple fractions Mixed numbers n/d 2nd [Un/d] Conversion b/w simple fraction and mixed number 2nd [n/d Un/d] Conversion b/w fraction and decimal Powers, roots, and inverses 2nd [f d] Square a value x 2 Cube a value Raise value to specified power < < Example (2 4 ) 2 4 < Square root 2nd [ ] Example ( 16): 2nd [ ] 16 Reciprocal x -1 5 th root of 8: Example (n th root): 5 2nd [ x ] 8 Pi PI (π) π Toggle The scientific calculator might show the results of certain calculations as a fraction - possibly involving pi or a square root. To convert this kind of result to a single number with a decimal point, you will need to use the toggle answer button circled in the picture below. Pressing this button will change the display from a fractional to a decimal format. Answer Toggle If you find this onscreen calculator difficult to use, raise your hand and ask the TA to provide you with a hand-held calculator. If available, you will be provided with a scientific or non-scientific calculator. Candidates are not permitted to bring their own calculator into the testing room. Exam Preparation Guide Mar 2018 13