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PHMSA Corrosion Control of Pipeline Systems
Exam QUESTIONS AND VERIFIED ANSWERS WITH
RATIONALES JUST RELEASED
PHMSA Corrosion Control of Pipeline Systems Exam
Most Commonly Used Title:
PHMSA Corrosion Control of Pipeline Systems Exam
PHMSA Pipeline Corrosion Control Certification Exam
PHMSA Pipeline Corrosion & Cathodic Protection Exam
PHMSA Corrosion Control Compliance Examination
EXAM COVERAGE
Fundamentals of Corrosion & Electrochemical Principles (Core Exam Area)
This is the highest-weighted section of the PHMSA Corrosion Control of Pipeline Systems Exam.
Candidates must understand the science of corrosion, electrochemical reactions, corrosion mechanisms,
and how corrosion affects the integrity and safety of gas and hazardous liquid pipeline systems. The
exam emphasizes corrosion identification, prevention strategies, and regulatory compliance under
federal pipeline safety standards. PHMSA corrosion programs are primarily governed by 49 CFR Part 192
(gas pipelines) and 49 CFR Part 195 (hazardous liquid pipelines).
Topics include corrosion fundamentals, electrochemical corrosion cells, anodes, cathodes, electrolytes,
metallic return paths, oxidation and reduction reactions, galvanic corrosion, stray current corrosion,
atmospheric corrosion, internal corrosion, external corrosion, microbiologically influenced corrosion
(MIC), stress corrosion cracking (SCC), erosion-corrosion, and corrosion rate factors.
Federal Pipeline Corrosion Regulations (49 CFR Parts 192 & 195)
A major exam domain focusing on PHMSA regulatory compliance.
Topics include 49 CFR Part 192 Subpart I (Corrosion Control), 49 CFR Part 195 corrosion requirements,
operator responsibilities, corrosion control programs, qualified personnel requirements, inspection
intervals, maintenance requirements, documentation, recordkeeping, atmospheric corrosion control,
and regulatory compliance.
Cathodic Protection (CP)
One of the most heavily tested sections on the examination.
Topics include cathodic protection principles, sacrificial anode systems, impressed current systems
(ICCP), rectifiers, anode beds, test stations, reference electrodes, pipe-to-soil potential measurements,
polarization, current requirements, CP criteria, troubleshooting cathodic protection systems,
interference testing, and cathodic protection monitoring.
Protective Coatings & External Corrosion Prevention
A major pipeline integrity domain.
Topics include protective coating systems, fusion-bonded epoxy (FBE), polyethylene coatings, tape
coatings, coating defects, coating inspections, holiday detection, coating repairs, coating deterioration,
soil exposure, moisture barriers, and coating quality assurance.
Internal Corrosion Control
A frequently tested section emphasizing pipeline product quality and corrosion mitigation.
Topics include internal corrosion mechanisms, water accumulation, carbon dioxide corrosion, hydrogen
sulfide corrosion, oxygen corrosion, corrosion inhibitors, pigging operations, cleaning programs, internal
inspections, fluid sampling, and monitoring corrosion rates.
Corrosion Monitoring & Inspection Techniques
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A critical technical area focusing on corrosion detection.
Topics include close interval surveys (CIS), direct current voltage gradient (DCVG), alternating current
voltage gradient (ACVG), pipe-to-soil surveys, corrosion coupons, electrical resistance probes, ultrasonic
testing, magnetic flux leakage (MFL), inline inspection (ILI), smart pigs, wall thickness measurements,
and corrosion monitoring equipment.
Pipeline Integrity Management & Direct Assessment
A major integrity management section.
Topics include External Corrosion Direct Assessment (ECDA), Internal Corrosion Direct Assessment
(ICDA), Stress Corrosion Cracking Direct Assessment (SCCDA), integrity assessments, risk assessment,
defect evaluation, excavation criteria, repair priorities, preventive maintenance, and integrity
management planning.
Pipeline Materials & Corrosion Mechanisms
Candidates must understand materials commonly used in pipeline construction and their corrosion
characteristics.
Topics include carbon steel, stainless steel, cast iron, ductile iron, coating compatibility, galvanic series,
metallurgical factors, weld corrosion, material degradation, corrosion-resistant materials, and
environmental effects on pipeline materials.
Pipeline Repairs & Corrective Actions
A practical maintenance section emphasizing corrosion remediation.
Topics include corrosion defect evaluation, repair sleeves, composite repairs, pipe replacement, coating
restoration, cathodic protection adjustments, leak prevention, maintenance planning, repair
documentation, and post-repair inspections.
Safety, Environmental Protection & Damage Prevention
A critical operational area.
Topics include pipeline safety procedures, confined space awareness, excavation safety, electrical safety
around cathodic protection systems, hazardous materials awareness, environmental protection
requirements, spill prevention, emergency response, damage prevention programs, and public safety
responsibilities.
Documentation, Records & Personnel Qualification
A frequently tested regulatory section.
Topics include corrosion records, inspection reports, test records, maintenance documentation,
qualification of corrosion personnel, operator qualification (OQ), regulatory reporting, audit
preparation, compliance documentation, and quality assurance requirements. PHMSA regulations
require corrosion control activities to be performed by or under the direction of qualified personnel.
Question 1
Under 49 CFR Part 192, which Subpart specifically addresses the corrosion control requirements for gas
pipelines?
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A) Subpart E
B) Subpart G
C) Subpart I
D) Subpart M
Correct Answer: C
Rationale: 49 CFR Part 192 Subpart I specifically addresses corrosion control requirements for gas
pipelines. This subpart establishes the minimum requirements for corrosion control programs, including
cathodic protection, protective coatings, and atmospheric corrosion monitoring.
Question 2
Under 49 CFR Part 195, what is the maximum interval allowed for conducting close-interval cathodic
protection surveys on pipeline systems?
A) 1 year
B) 2 years
C) 3 years
D) 5 years
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Correct Answer: C
Rationale: 49 CFR Part 195 requires that close-interval surveys be conducted at intervals not exceeding 3
years. The interval is established based on corrosion control program effectiveness and can be extended
with documented justification.
Question 3
What is the minimum cathodic protection potential required for a steel pipeline in contact with soil per
the -0.85 V criterion?
A) -0.85 V as measured with a copper-copper sulfate reference electrode, with IR drop considered
B) -0.85 V as measured with a copper-copper sulfate reference electrode, without IR drop consideration
C) -0.95 V as measured with a copper-copper sulfate reference electrode with IR drop considered
D) -0.75 V as measured with a standard calomel electrode
Correct Answer: A
Rationale: The -0.85 V criterion is the minimum cathodic protection potential required to prevent
corrosion on steel pipelines in contact with soil, measured with a copper-copper sulfate reference
electrode with IR drop considered. This is a fundamental CP criterion in 49 CFR Part 192 and Part 195.
PHMSA Corrosion Control of Pipeline Systems
Exam QUESTIONS AND VERIFIED ANSWERS WITH
RATIONALES JUST RELEASED
PHMSA Corrosion Control of Pipeline Systems Exam
Most Commonly Used Title:
PHMSA Corrosion Control of Pipeline Systems Exam
PHMSA Pipeline Corrosion Control Certification Exam
PHMSA Pipeline Corrosion & Cathodic Protection Exam
PHMSA Corrosion Control Compliance Examination
EXAM COVERAGE
Fundamentals of Corrosion & Electrochemical Principles (Core Exam Area)
This is the highest-weighted section of the PHMSA Corrosion Control of Pipeline Systems Exam.
Candidates must understand the science of corrosion, electrochemical reactions, corrosion mechanisms,
and how corrosion affects the integrity and safety of gas and hazardous liquid pipeline systems. The
exam emphasizes corrosion identification, prevention strategies, and regulatory compliance under
federal pipeline safety standards. PHMSA corrosion programs are primarily governed by 49 CFR Part 192
(gas pipelines) and 49 CFR Part 195 (hazardous liquid pipelines).
Topics include corrosion fundamentals, electrochemical corrosion cells, anodes, cathodes, electrolytes,
metallic return paths, oxidation and reduction reactions, galvanic corrosion, stray current corrosion,
atmospheric corrosion, internal corrosion, external corrosion, microbiologically influenced corrosion
(MIC), stress corrosion cracking (SCC), erosion-corrosion, and corrosion rate factors.
Federal Pipeline Corrosion Regulations (49 CFR Parts 192 & 195)
A major exam domain focusing on PHMSA regulatory compliance.
Topics include 49 CFR Part 192 Subpart I (Corrosion Control), 49 CFR Part 195 corrosion requirements,
operator responsibilities, corrosion control programs, qualified personnel requirements, inspection
intervals, maintenance requirements, documentation, recordkeeping, atmospheric corrosion control,
and regulatory compliance.
Cathodic Protection (CP)
One of the most heavily tested sections on the examination.
Topics include cathodic protection principles, sacrificial anode systems, impressed current systems
(ICCP), rectifiers, anode beds, test stations, reference electrodes, pipe-to-soil potential measurements,
polarization, current requirements, CP criteria, troubleshooting cathodic protection systems,
interference testing, and cathodic protection monitoring.
Protective Coatings & External Corrosion Prevention
A major pipeline integrity domain.
Topics include protective coating systems, fusion-bonded epoxy (FBE), polyethylene coatings, tape
coatings, coating defects, coating inspections, holiday detection, coating repairs, coating deterioration,
soil exposure, moisture barriers, and coating quality assurance.
Internal Corrosion Control
A frequently tested section emphasizing pipeline product quality and corrosion mitigation.
Topics include internal corrosion mechanisms, water accumulation, carbon dioxide corrosion, hydrogen
sulfide corrosion, oxygen corrosion, corrosion inhibitors, pigging operations, cleaning programs, internal
inspections, fluid sampling, and monitoring corrosion rates.
Corrosion Monitoring & Inspection Techniques
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A critical technical area focusing on corrosion detection.
Topics include close interval surveys (CIS), direct current voltage gradient (DCVG), alternating current
voltage gradient (ACVG), pipe-to-soil surveys, corrosion coupons, electrical resistance probes, ultrasonic
testing, magnetic flux leakage (MFL), inline inspection (ILI), smart pigs, wall thickness measurements,
and corrosion monitoring equipment.
Pipeline Integrity Management & Direct Assessment
A major integrity management section.
Topics include External Corrosion Direct Assessment (ECDA), Internal Corrosion Direct Assessment
(ICDA), Stress Corrosion Cracking Direct Assessment (SCCDA), integrity assessments, risk assessment,
defect evaluation, excavation criteria, repair priorities, preventive maintenance, and integrity
management planning.
Pipeline Materials & Corrosion Mechanisms
Candidates must understand materials commonly used in pipeline construction and their corrosion
characteristics.
Topics include carbon steel, stainless steel, cast iron, ductile iron, coating compatibility, galvanic series,
metallurgical factors, weld corrosion, material degradation, corrosion-resistant materials, and
environmental effects on pipeline materials.
Pipeline Repairs & Corrective Actions
A practical maintenance section emphasizing corrosion remediation.
Topics include corrosion defect evaluation, repair sleeves, composite repairs, pipe replacement, coating
restoration, cathodic protection adjustments, leak prevention, maintenance planning, repair
documentation, and post-repair inspections.
Safety, Environmental Protection & Damage Prevention
A critical operational area.
Topics include pipeline safety procedures, confined space awareness, excavation safety, electrical safety
around cathodic protection systems, hazardous materials awareness, environmental protection
requirements, spill prevention, emergency response, damage prevention programs, and public safety
responsibilities.
Documentation, Records & Personnel Qualification
A frequently tested regulatory section.
Topics include corrosion records, inspection reports, test records, maintenance documentation,
qualification of corrosion personnel, operator qualification (OQ), regulatory reporting, audit
preparation, compliance documentation, and quality assurance requirements. PHMSA regulations
require corrosion control activities to be performed by or under the direction of qualified personnel.
Question 1
Under 49 CFR Part 192, which Subpart specifically addresses the corrosion control requirements for gas
pipelines?
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A) Subpart E
B) Subpart G
C) Subpart I
D) Subpart M
Correct Answer: C
Rationale: 49 CFR Part 192 Subpart I specifically addresses corrosion control requirements for gas
pipelines. This subpart establishes the minimum requirements for corrosion control programs, including
cathodic protection, protective coatings, and atmospheric corrosion monitoring.
Question 2
Under 49 CFR Part 195, what is the maximum interval allowed for conducting close-interval cathodic
protection surveys on pipeline systems?
A) 1 year
B) 2 years
C) 3 years
D) 5 years
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Correct Answer: C
Rationale: 49 CFR Part 195 requires that close-interval surveys be conducted at intervals not exceeding 3
years. The interval is established based on corrosion control program effectiveness and can be extended
with documented justification.
Question 3
What is the minimum cathodic protection potential required for a steel pipeline in contact with soil per
the -0.85 V criterion?
A) -0.85 V as measured with a copper-copper sulfate reference electrode, with IR drop considered
B) -0.85 V as measured with a copper-copper sulfate reference electrode, without IR drop consideration
C) -0.95 V as measured with a copper-copper sulfate reference electrode with IR drop considered
D) -0.75 V as measured with a standard calomel electrode
Correct Answer: A
Rationale: The -0.85 V criterion is the minimum cathodic protection potential required to prevent
corrosion on steel pipelines in contact with soil, measured with a copper-copper sulfate reference
electrode with IR drop considered. This is a fundamental CP criterion in 49 CFR Part 192 and Part 195.
