written exam preparation guide

Exam Preparation Guide—May 2017 | 1

Refining Corrosion TechnologistNACE-RCT-001

NACE Cathodic Protection Specialist (CP 4) Written ExamNACE-CP4-001Exam Preparation Guide June 2017

Copyright ©2016 by NACE International Institute. All rights reserved.

Exam Preparation Guide—June 2017 | 2

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 .................................................................................................................................................................. 9

Other ........................................................................................................................................................................... 9

Calculator ................................................................................................................................................................10

NACE-CP4-001


IntroductionThe Cathodic Protection Specialist (CP 4) written 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 66 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 interpretation of CP data and troubleshooting.

Test NameNACE- Cathodic Protection Specialist Level 4 Written Exam

Test Code NACE-CP4-001

Time 4 hours*Number of Questions 66

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.

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 AudienceCathodic 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 time includes 4 minutes for the non-disclosure agreement and 6 minutes for the system tutorial.

NACE-CP4-001


Requirements

Cathodic Protection Specialist (CP4)Requirements for Cathodic Protection Specialist (CP4):

n 1 Prerequisite nWork Experience n 2 Core exams n Application

The following prerequisite is required

Successful completion of Cathodic Protection Technologist (CP 3), or equivalent training

Work Experience Requirements

12 years verifiable CP work experience And2 year post high school training from approved math / science technical / trade school

6 years verifiable CP work experience And4 year physical science or engineering degree Andadvanced physical science or engineering degreeOr PE, PE Eng or equivalent

Core Exam RequirementsThe following exams are required: (2 core exams required)

Cathodic Protection level 4 exam (multiple choice) NACE- CP4-W-001

Cathodic Protection level 4 exam (essay / formula) NACE- CP4-E-001

Application Requirements

Approved Cathodic Protection Specialist (CP4) application

Submit Application - candidates must apply for this certification by submitting an on-line application which is subject to approval. Applications must be submitted within 3 years of successful completion of exam.

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

§ Renewal Fee (Members $240.00 USD; Non-members $450.00 USD)

Upon successful completion of requirements, the candidate will be awarded a Cathodic Protection Specialist (CP 4) Certification.

*Approval required

NACE-CP4-001

Note: Completion of course does not entitle the candidate to the certification.


Exam Blue PrintNOTE: At the end of the CBT exam the candidate will receive a bar chart of strengths and weaknesses that corre-spond to these Domains.

Domain 1- Reference Cells - 1-3%

§ 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.

§ 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.

Domain 2 - Record Keeping and Administrative - 1-2%

§ 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 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.

Domain 3 - Field Tests - 1-4%

§ 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.

NACE-CP4-001


§ 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 4 - DC Stray Current Interference - 3-6%

§ 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

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.

Domain 5 - Corrosion Theory - 4-7%

§ 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.)

§ 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.

Domain 6 - Polarization - 3-6%

§ Understand the cause and effect of polarization in a galvanic cell

§ Understand activation, concentration and resistance polarization and the mathematical

expressions of these concepts. § Understand the factors that affect polarization

(area, temperature, relative movement, ion concentration, oxygen concentration)

Domain 7 - Cathodic Protection - 8-12%

§ 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 of galvanic and impressed current cathodic 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 the IR drop and apply correction techniques as needed.

NACE-CP4-001


§ 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

Domain 8 - Design - 30-40%

§ 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

§ 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 and 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 Specialist. 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. The magnitude of geomagnetically induced voltage on a pipeline is

I. Directly proportional to coating resistance

II. Inversely proportional to pipe length

III. Dependent on the pipelines location relative to the geomagnetic poles.

IV. Varies with time of day

A. I onlyB. II & III onlyC. I, II, IV onlyD. I, III, IV only

NACE-CP4-001


2. Which if the following electrical interference situations causes deleterious effects?

A. Stray DC current pick-up on a bare low carbon steel pipe

B. A stray AC current density of <2 mA/cm2 on steel

C. A stray current discharge from a cast iron pipe

D. A polarized potential on steel shifted from -1080 mVcse to -880 mVcse

Answer Key1. DReference: NACE Cathodic Protection Technologist level 3 Course Material

2. C

Reference: NACE Cathodic Protection Technologist level 3 Course Material

PreparationTraining

§ NACE Cathodic Protection Technologist (CP 3)- Course

Strongly Recommended Prerequisite Training

§ NACE Cathodic Protection Technologist- Course CP 3

§ NACE Cathodic Protection Technician- Course CP2

§ 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.

Papers

§ Ansuini, Frank J., James R. Dimond, “Factors Affecting the Accuracy of Reference Electrodes”,

Materials Performance, 33, 11 (1994): pp. 14-17.

NACE-CP4-001


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

NACE-CP4-001


Calculators

Students will have access to either a TI Standard or TI Scientific calculator for use during the CBT

Exam.

Standard Calculator Standard Mode Functions

Scientific Calculator Scientific Mode Functions

Add +Subtract -Multiply xDivide ÷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

Add +Subtract -Multiply xDivide ÷Negative (-)Percentage 2nd [%]

Square Root √ Example: 2nd √ 4 enter

Reciprocal (Inverse) X-1 Example: 2 X-1 enter

Store value to variable sto Xyzt Example: 3 * 5 enter sto Xyzt enter

Access variable Xyzt or2nd [recall]

Example: 7 + 2nd [recall] enter enter

s s

Standard (Floating Decimal) Notation (digits to the left and right of decimal

mode menu optionsNORM SCI ENG e.g. 123456.78FLOAT 0 1 2 3 4 5 … e.g. 123456.7800

Scientific Notation(1 digit to the left of decimal and appropriate power of 10)

mode menu optionsNORM SCI ENG e.g. 1.2345678*105

Engineering Notation(numer from 1 to 999 times 10 to an integer power that is a multiple of 3)

mode menu optionsNORM SCI ENG e.g. 123.45678*103

Numeric Notation

NACE-CP4-001


Simple fractions n/d

Mixed numbers 2nd [Un/d]

Conversion b/w simple fraction and mixed number 2nd [n/d Un/d]

Conversion b/w fraction and decimal2nd [f d]

Fractions

s

s

s

sSquare a value x2

Cube a value

Raise value to specified powerExample (24)

2 4

Square root 2nd [√]Example (√16):

2nd [√] 16

Reciprocal x-1

Example (nth root):5th root of 8:5 2nd [x√] 8

Powers, roots, and inverses

<< <

PiPI (π) π

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.

Toggle

Answer Toggle

f 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.

NACE-CP4-001

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