Refining Corrosion Technologist NACE-RCT-001 NACE Cathodic Protection Specialist (CP 4) Essay 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...10 Description of Questions...10 Sample Questions...10 Preparation...10 Training...10 Suggested Study Material...10 Books...10 Papers...11 Standards...11 Other...11 Exam Preparation Guide Mar 2018 2
Introduction The Cathodic Protection Specialist (CP 4) essay exam is designed to assess whether a candidate has the requisite knowledge and skills that a minimally qualified Cathodic Protection Specialist (CP 4) must possess. The exam consists of 2 essay 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 interpretation of CP data and troubleshooting. Test Name NACE- Cathodic Protection Specialist (CP 4) Essay Exam Test Code NACE-CP3-001 Time 2 ½ hours Number of Questions 2 Format Paper/pencil NOTE: The CBT exam and the essay exam are scored separately and candidates must pass both exams. NOTE: The course manual is allowed in the exam. NOTE: Cathodic Protection Specialist (CP 4) essay exam is only given at the conclusion of the NACE Cathodic Protection Specialist Course. Separate arrangements should be made to take this portion of the exam should the candidate choose not to attend the full course. Target Audience Cathodic Protection Specialist (CP 4) certification is geared toward those persons involved in the design, installation, and maintenance of cathodic protection systems. Prior to taking the exam or the NACE training course, students must have completed college or university-level courses in algebra, geometry, and trigonometry, and must have significant amounts of practical experience in cathodic protection. NOTE: There is NOT a direct progression from Cathodic Protection Technologist (CP 3) to Cathodic Protection Specialist (CP 4). Substantial experience, beyond that of a Cathodic Protection Technologist (CP 3), 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 Technologist (CP 3) course is strongly recommended before attempting Cathodic Protection Specialist (CP 4). However, additional experience and education are also recommended. Exam Preparation Guide Mar 2018 3
Requirements Cathodic Protection Specialist (CP4) Requirements for Cathodic Protection Specialist (CP4): 1 Prerequisite Work Experience 2 Core exams Application The following prerequisite is required None Work Experience Requirements 12 years verifiable CP work experience And 2 year post high school training from approved math / science technical / trade school 6 years verifiable CP work experience And 4 year physical science or engineering degree And advanced physical science or engineering degree Or PE, PE Eng or equivalent Core Exam Requirements The following exams are required: (2 core exams required) Cathodic Protection Specialist (CP 4) closed book exam (multiple choice, with relevant references) NACE- CP4-W-001 Cathodic Protection Specialist (CP 4) exam (essay / formula) NACE- CP4-E-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 Specialist (CP 4) Certification. *Approval required Exam Preparation Guide Mar 2018 4
Exam Blue Print Domain 1- Basics 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. 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 of 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 metal objects that are underground or otherwise immersed in an electrolyte. Understand the concept of shielding and how it can affect metallic objects that are cathodically protected. Understand the principles of magnetism and how it applies to transformers Domain 2 - Atmospheric Perform periodic atmospheric corrosion inspections and document your findings according to company procedures. Domain 3 - Insulators and Shorts Understand the need for insulation or isolation between facilities. Understand the effect a metallic short can have on your CP system. Test to see if an insulator is shorted using pipe-to-soil readings Test an insulator with an electronic insulator checking instrument Locate and clear shorts on an underground Domain 4 - Instruments Understand the operation of a Volt-Ohm meter (Multimeter) as to 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 Domain 5 - CP Current Source Install galvanic anodes, document the installation and test to insure proper operation. pipeline system. Understand the need for insulation or isolation between facilities. Understand the effect a metallic short can have on your CP system. Test to see if an insulator is shorted using pipe-to-soil readings Test an insulator with an electronic insulator checking instrument Vibroground, Nilsson or equivalent instrument. Conduct soil resistivity measurements by using a Soil Box. Conduct single-point soil resistivity readings with a Collins Rod Install interrupters in rectifiers or bonds for the purpose of taking on/off readings Understand the various types of pipe locating instruments and be able to utilize them to locate pipelines or cables in all underground environments. Obtain periodic rectifier readings. Troubleshoot a rectifier installation by using a Exam Preparation Guide Mar 2018 5
Volt-Ohm meter (Multimeter) to follow the input AC voltage through the transformer to Domain 6 - CP Test Leads Install test leads for a potential test station according to company specifications. Install jumper test leads across an insulated flange according to company specifications. Install test leads for a critical bond according to company specifications. Install test leads for a mv Drop configuration in order to measure current flow in a pipeline. Domain 7 - Shunts Understand how to determine the amount of current flowing through various size shunts by reading the mv drop across it with a Volt-Ohm meter and applying the correct conversion factor. 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. Domain 8 - Periodic Surveys Conduct annual pipe to soil surveys on all facilities. Conduct rectifier readings. Conduct surveys of bonds. Conduct surveys of diodes or current Domain 9 - Reference Cells Understand the construction and operation of reference cells and maintain them in a manner that will provide comparative readings. Install permanent reference cells and check them periodically to insure that are in good working order. Domain 10 - Record Keeping and Administrative Record readings from periodic surveys according to the methods provided by your company. Keep all records required by the DOT for the life of the facility involved. Use computer word processing or spread sheets to prepare reports, letters and other the stack and the DC from the stack to the load. Install test leads for a foreign line crossing. Make attachments to a pipe or tank by silver soldering the connection. Make attachments to a pipeline or tank by using an exothermic weld kit. Make repairs and/or splices to bond leads, header cables and test leads. 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 output current of a rectifier with a broken amp meter. Read shunts that are installed in galvanic anodes to determine the amount of current it s putting out. reversing switches. Conduct soil resistivity surveys. Collect data on external coupon test stations. Conduct offshore platform and riser surveys Abide by the recommendations in the MSDS sheet pertaining to the handling and disposal of Copper Sulfate. Use an antimony half-cell in comparison to a copper/copper sulfate half-cell for determining the ph of soils. necessary correspondence. Understand how to read your alignment sheets and other system maps and be able to provide accurate locations where work was done or new facilities installed. Exam Preparation Guide Mar 2018 6
Domain 11 - Field Tests 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 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/ 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) Domain 12 - DC Stray Current Interference 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 13 - AC Mitigation Understand the safety requirements when installing test stations under high voltage power lines 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 Domain 14 - Rectifiers Exam Preparation Guide Mar 2018 7
Be capable of reading electrical schematics Perform efficiency test on rectifiers. Install new rectifiers Repair rectifiers that have received damage from surges or lightning. Know how to change the connections of a rectifier to receive 240 volts or 120 volts input AC. Know how to test a transformers primary and secondary out of the circuit with an ohm meter. Know how to test a transformer in the circuit with an AC voltmeter. Know how to test a diode with an ohm meter. Understand the differences in a selenium and silicon diodes and the advantages and disadvantaged of each when used in a CP rectifier. Understand the various type of circuit breakers that can be used in CP rectifiers and the advantages and disadvantages of each Understand the circuits required in CP rectifiers for single and three phase AC inputs and be able to troubleshoot them Understand the various type of circuit configurations that can provide rectification Full wave, single wave, full wave bridge Understand the effects of filtering configurations used in CP rectifiers and the advantages each can provide Know how to modify a CP rectifier that is found to be interfering with EFM, SCADA or radio communication signals Installation of chokes when the pulsating dc is causing problems with EFM calibration Domain 15 - Internal Collect data on ER probes. Domain 16 - Corrosion Theory 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 17 - Polarization Understand the cause and effect of polarization in a galvanic cell Understand activation, concentration and resistance polarization and the mathematical Domain 18 - Cathodic Protection Understand the concept cathodic protection and be knowledgeable of the components required for both galvanic and impressed current systems. Be able to design and install simplistic forms 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) of galvanic and impressed current cathodic protection facilities. Understand the relationship between cathodic protection and other methods of corrosion mitigation Exam Preparation Guide Mar 2018 8
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 the IR drop and apply correction techniques as needed. Domain 19 - Training Provide one-on-one training for understudies in the proper use of CP instruments Domain 20 - Codes and Compliance Should have a good working knowledge of appropriate regulations that apply to the products, transportation or storage means being utilized by your company. Should know the reports and other documentation that is required by the agencies that inspect yourfacilities. Domain 21 - Corrosion Analysis 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 22 - Design 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 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 Present formal training sessions on Basic and Advanced Cathodic Protection Should have a good understanding of the National Electrical Code as it relates to cathodic protection facilities in all divisions and classes. Should have a good working knowledge of grounding practices and lightning protection and how it can effect a CP system 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 Exam Preparation Guide Mar 2018 9
Types of Questions Description of Questions The questions on this exam include an essay and a computation. The questions are based on the knowledge and skills required in the cathodic protection industry for a Cathodic Protection Specialist (CP 4). 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. A client has hired you to evaluate the cathodic protection level for a small tank farm consisting of 4 120 foot diameter storage tanks. These tanks are surface mounted. Cathodic protection for the tanks consists of distributed anodes placed around each tank in a ring and spaced approximately 10 feet from the tank. Each ring consists of 12 graphite anodes centered in an 8 inch diameter x 10 foot long coke column with a total depth of 15 feet. The tanks are electrically interconnected by an above ground piping system but are isolated from other structures. a. Indicate the approach you would employ to evaluate the level of protection on the tanks. b. Indicate any problems you might anticipate. c. Indicate how you would resolve each problem anticipated including any tests that might be required. Preparation Training NACE Cathodic Protection Specialist (CP 4) - Course Strongly Recommended Prerequisite Training NACE Cathodic Protection Technologist (CP 3) - Course NACE Cathodic Protection Technician (CP 2) - Course NACE Cathodic Protection Tester (CP1) - Course Suggested Study Material NACE Cathodic Protection Specialist (CP4) - course 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. Exam Preparation Guide Mar 2018 10
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 Control of External Corrosion on Underground or Submerged Metallic Piping Systems SP0285 Corrosion Control of Underground Storage Tank Systems by Cathodic Protection SP0388 Impressed Current Cathodic Protection of Internal Submerged Surfaces of Carbon Steel Water Storage Tanks SP0177 Mitigation of Alternating Current and Lightning Effects on Metallic Structures and Corrosion Control Systems SP0575 Internal Cathodic Protection (CP) Systems in Oil-Treating Vessels SP0176 Corrosion Control of Submerged Areas of Permanently Installed Steel Offshore Structures Associated with Petroleum Production RP0193 External Cathodic Protection of On-Grade Carbon Steel Storage Tank Bottoms SP0196 Galvanic Anode Cathodic Protection of Internal Submerged Surfaces of Steel Water Storage Tanks SP0290 Impressed Current Cathodic Protection of Reinforcing Steel in Atmospherically Exposed Concrete Structures SP0200 Steel-Cased Pipeline Practices TM0497 Measurement Techniques Related to Criteria for Cathodic Protection on Underground or Submerged Metallic Piping Systems TM0101 Measurement Techniques Related to Criteria for Cathodic Protection of Underground Storage Tank Systems Other 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