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Situation 2: You are assigned as the bundle inspector during a chemical plant turnaround. You are organized, have copies of all the old inspection data, and are basically having a great time inspecting remote from all the normal turnaround hub-bub. But one of the last bundles inspected has unexpected deep corrosion and is made of an exotic alloy. The word quickly gets out and suddenly the key Operations & Maintenance Leads show up at the bundle cleaning area. Their first question is not, Hows the weather?, or, Hows the bundle cleaners doing?, but ... Will the bundle make the next operational run??? You sheepishly look at the past records and tell them you will not know until after you have plugged the data into the computer. They walk away disgusted, muttering something about your lack of ability. The result: Youre embarrassed!
Situation 3: A vessel fails and results in a tremendous fire. Two contract craftsmen are injured and will have permanent disabilities. During the post-fire investigation, it is determined that you made a mistake when calculating the corrosion rate. The actual corrosion rate was 0.020 ipy, but you missed a decimal and used 0.002 ipy! The primary cause of the fire was your mistake. The result: Youre embarrassed! You sorrow for those hurt, youre depressed, you may be fired, you may have your API certs pulled, and youll probably have to admit your mistakes in a lawsuit. All because of a silly little decimal point!
Whats a Subscript?
Before proceeding further, lets understand subscripts! In math, subscripts are used to differentiate between values that use a similar symbol. For example, t often represents thickness. However, many thicknesses are important to us, e.g. nominal thickness, minimum thickness, etc. Subscripts clearly communicate which thickness you are using in a calculation. Always use subscripts in Corrosion Rate calculations. YES THAT MEANS YOU!
tmin
a subscript
Table 1 lists the most common thicknesses and the common math symbol.
Thickness Nominal thickness Initial thickness Previous thickness Last thickness Retirement thickness tnom tini tpre tlast
Math Symbol
or tnominal or tinitial or tbase or tprevious or tcurrent or tactual or tmin or tminimum
Notes
Based on std pipe or plate thickness At a TML - First thickness reading. Also called base or first reading. At a TML - The previous(prior) thickness reading At a TML - The most recent thickness reading. Also called current or actual Minimum allowed thickness. Also called minimum thickness
tretirement
What is a Speed?
A Speed is how fast something moves. Speed always has units of a distance per time. Speeds are expressed different ways depending on what units are most convenient. For example, traveling in a car, speed is measured in miles-per-hour (mph). It would be ridiculous to say were traveling 3,801,600 inchesper-hour, but thats exactly the same as 60 mph. Typical speed units are illustrated in Table 2.
US Speed Units miles per hour feet per second miles per second inches per year, or mils per year
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Speed =
= 56.7 mph
Key! All speeds always use the term per, as in miles-per-hour, or inches-per-year. In mathematical terms, what is the meaning of per? PER means DIVIDED BY. Remember this and you will always be able to write the formula for a corrosion rate or any other speed. So miles-per-hour is just miles-divided by-hours.
Determining a Speed
Automobile Speed (mph): Corrosion Speed (ipy): Miles Traveled DIVIDED BY Hours Traveled Inches Traveled DIVIDED BY Years Traveled
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Travel direction El Paso 0 Fort Stockton 220 San Antonio 555 Speed = Houston 750 @ 3:00 p.m. Distance Traveled Time Traveled 880 - 750 = 3:00 1:00 130 miles 2 hours = 65 mph Louisiana Border 880 @ 1:00 p.m.
Mile Markers
Speed =
The Key!!! Understand these simple steps! When calculating the equipments Next Inspection Date, we use the same basic steps!
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Corrosion Rate =
Thickness Data
TML # 01 Jan. 2003 0.450 Jan. 1993 0.500
CR = CR =
tprevious tlast time 0.500 0.450 2003 1993 = 0.050 10 = 0.005 ipy
Always add units to your answer! Dont say the corrosion rate is 0.005. Is that 0.005 mm/yr or 0.005 ft/second?
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Time to Practice: Calculate the Corrosion Rate in the following exercises. An Answer Key is provided in the website as another pdf file to download.
CR =
CR =
CR =
CR =
ipy
Always write the formula! Failure to write the formula is the Number 1 cause of calculation mistakes!
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Thickness Data
TML # TH-3 March 2004 0.280 March 1997 0.350
Convert thickness readings to mils; 280 mils & 350 mils tprevious tlast time 350 280 2004 1997 = 70 7 = 10 mpy
Since we used mils, the units on the answer are in mils-per-year
CR = CR =
Thickness Data
TML # 32 Nov. 2003 0.410 Nov. 1981 0.480
CR =
CR =
mpy
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Month # 4th
Thickness Data
TML # N-2 March 2004 0.275 Oct 2001 0.288
Step 2 - Calc Corrosion Rate CR = CR = tprevious tlast time 0.288 0.275 2004.25 2001.83 = 0.013 2.42 = 0.0054 ipy
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Thickness Data
TML # HD-2 Sept 2003 0.521 April 1999 0.565
CR =
ipy
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Remaining Life =
tlast tmin CR
Note! The Remaining Life for an Equipment Item is based on the TML with the lowest Remaining Life!
Thickness Data
TML # 6 tminimum 0.270 Jan. 2004 0.300 Jan. 1994 0.350
Life =
Life =
= 6 yrs
The Equipment Life at this TML is 6 years from the last inspection date (January 2004).
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TML Data
TML # D-7 Corrosion Rate 0.007 ipy
tminimum
0.150
Life =
Life =
yrs
TML Data
TML # D-8 Corrosion Rate 0.003 ipy
tminimum
0.150
Life =
Life =
yrs
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Vessel Data
Vessel V-100 Remaining Life 12 yrs Last Inspection January 2004
Step 1 - Calculate the Interval Interval = Lesser of life or 10 yrs (Per API 510 Code) = Lesser of: 12 x = 6 yr, or 10 yrs = 6 yrs Step 2 - Calculate the Next Inspection Date (NID) NID = Last Inspection Date + Interval = January 2004 + 6 yrs = January 2010
Vessel Data
Vessel ID V-200 Remaining Life 14 yrs Last Inspection March 2003
Step 1 - Calculate the Internal Interval Interval = Lesser of: __________________________________ = Lesser of: __________________________________ = Step 2 - Calculate the Next Inspection Date (NID) NID = = =
Remember! Always write the formula!
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Vessel Data
Vessel V-300 Remaining Life 9.5 yrs Last Inspection October 2003
Step 1 - Calculate the Interval Interval = Lesser of life or 10 yrs (Per API 510 Code) = Lesser of: 9.5 x = 4.75 yr, or 10 yrs = 4.75 yrs Step 2 - Convert the Last Inspection Date to a Number) October 2003 = 2003-10/12 = 2003.83 Step 3 - Calculate Next Inspection Date (NID) NID = Late Inspection Date + Interval = 2003.83 + 4.75 yrs = 2008.58
Step 4 - Convent the Partial Year to Months Partial Year is 0.58 yr (there are 12 months in a year) # of Months = 0.58 yr x 12 months/yr = 6.96 months = 7 months The 7th month is July Step 5 - The Final Answer July 2008
To convert year & months Partial Yr to Months: # of Months = Partial Year x 12 Months to Partial Yr: Partial Year = # of Months / 12
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Last Insp Date V-10 V-20 V-30 V-40 V-50 April 2001 Feb. 2002 Sept 2003 Nov. 2001 May 2003
Short-Term Rate =
Long-Term Rate =
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Jan 2003
0.440
Jan 1998
0.465
Jan 1995
0.480
Jan 1993
0.500
Step 1 - Calculate Short-Term Corrosion Rate ST Rate = tprevious tlast time period = 465 440 5 = 5 mpy
Step 2 - Calculate Long-Term Corrosion Rate LT Rate = tfirst tlast time period = 500 440 10 = 6 mpy
Step 3 - Pick the Controlling Corrosion Rate (the highest) Highest between: 5 & 6 mpy = 6 mpy Step 4 - Calculate Remaining Life Life = tlast tmin = Corrosion Rate 440 380 6 = 10 yrs
This problem is worked in mils. If you work it in inches, the answer is the same!
Which Corrosion Rate should you use? Long-Term or Short-Term? Select the larger rate!
What do we do with the Reading on January 1995? For this TML, absolutely nothing! Its not needed for either the short or long-term calculations.
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Jun 2003
0.718
Jun 1997
0.742
Jun 1994
0.745
Jun 1990
0.750
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May 2003
0.454
Oct 1998
0.477
May 1995
0.492
Jan 1991
0.500
Step 1 - Convert Dates to Numbers May 2003 Oct 1998 Jan 1991 = 2003-5/12 = 2003.42 = 1998-10/12 = 1998.83 = 1991-1/12 = 1991.08
Step 2 - Calculate Short-Term Corrosion Rate ST Rate = tprevious tlast time period = 477 454 = 2003.42 1998.83 23 4.59 = 5 mpy
Step 3 - Calculate Long-Term Corrosion Rate LT Rate = tfirst tlast time period = 500 454 2003.42 1991.08 = 46 = 3.7 mpy 12.34
Step 4 - Pick the Controlling Corrosion Rate (the highest) Highest between: 5 & 3.7 mpy = 5 mpy Step 5 - Calculate Remaining Life Life = tlast tmin = Corrosion Rate 454 395 5 = 59 5 = 11.8 yrs
Step 6 - Calculate Inspection Interval Per API 510: Lesser of Life (0.5 x 11.8 = 5.9 yr) or 10 yrs = 5.9 yrs Step 7 - Calculate the Next Inspection Date (NID) NID NID = Last Insp Date + Interval = 2003.42 + 5.9 = 2009.32
Step 8 - Convert Partial Year to Month # of Months = 0.32 x 12 = 3.8 months, about 4th month (April) Step 9 - Final Answer: April 2009
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tminimum
0.212
Feb 2003
0.288
Jun 1992
0.305
Nov 1985
0.322