SECTION 7-INSPECTION DATA EVALUATION, ANALYSIS, AND RECORDING
7.1 Corrosion Rate Determination
7.1.1 Existing Pressure Vessels
[Link] Corrosion rate for thinning damage mechanisms is determined by the difference between two thickness readings
divided by the time interval between the readings. The determination of corrosion rate may include thickness data collected at
more than two different times. Suitable use of short-term versus long-term corrosion rates shall be determined by the inspector.
Short-term corrosion rates are typically determined by the two most recent thickness readings whereas long-term rates usc the
most recent reading and one taken earlier in the life of the equipment. These different rates hclp identifY recent corrosion mecha-
nisms from those acting over the long-term.
The long-term (LT) corrosion rate shall be calculated from the following formula:
tinitial- factual
Corrosion rate(LT) =
time between tinitial and taelual(yearS)
The short-term (ST) corrosion rate shall be calculated from the following formula:
Corrosion rate(ST) = [previous - toe/uol
time between [previous and lae,ua,(years)
where
tinitial = the initial thickness at the same CML as tactual. It's either the fIrst thickness measurement at this CML or the
thickness at the start ofa new corrosion rate environment, in in. (mm).
tactual = the actual thickness of a CML, in in. (mm), measured during the most recent inspection.
tprevious = the previous thickness measured during the prior inspection. It is at the same location as tactual measured during a
previous inspection, in in. (mm).
[Link] Long-term and short-term corrosion rates should be compared as part of the data assessment. The inspector, in consul-
tation with a corrosion spe~ialist, shall select the corrosion rate that best reflects the current conditions.
7.1.2 Newly Installed Pressure Vessels or Changes in Service
For a new vessel or for a vessel for which service conditions are being changed, one of the following methods shall be used to
determine the vessel's probable corrosion rate. The remaining life and inspection interval can be estimated from this rate.
a. A corrosion rate may be calculated from data collected by the owner/user on vessels operating in the same or similar service. If
data on vessels operating in the same or similar service are not available, then consider the other alternatives.
b. A corrosion rate may be estimated from the owner/user's experience.
c. A corrosion rate may be estimated from published data on vessels in same or similar service.
d. If the probable corrosion rate cannot be determined by any of the above items, an on-stream determination shall be made after
approximately 1000 hours of service by using suitable corrosion monitoring devices or actual thickness measurements of the ves-
sel. Subsequent determinations shall be made at appropriate intervals until the corrosion rate is established.
If it is later determined that an inaccurate corrosion rate was assumed, the corrosion rate in the remaining Ii fe calculations shall be
changed to the actual corrosion rate.
7.2 Remaining Life Calculations
7.2.1 The remaining life of the vessel (in years) shall be calculated from the following formula:
.. 1;'1' t oclual - t required
R emaznzng IJe = .
corrosIOn rate
7-1
7-2 API 510
where
taclual the actual thickness of a CML, in in. (mm), measured during the most recent inspection.
trequired = the required thickness at the same CML or component, in in. (mm), as the taclual measurement. It is computed by the
design formulas (e.g., pressure and structural) and does not include corrosion allowance or manufacturer's toler-
ances.
7.2.2 A statistical analysis may be used in the corrosion rate and remaining life calculations for the pressure vessel sections.
This statistical approach may be applied for assessment of substituting an intemal inspection (see 6.5.2.1b) or for determining the
internal inspection interval. Care must be taken to ensure that the statistical treatment of data results reflects the actual condition
of the vessel section especially those subject to localized corrosion. Statistical analysis may not be applicable to vessels with ran-
dom but significant localized corrosion.
7.3 Maximum Allowable Working Pressure Determination
7.3.1 The MAWP for the continued use of a pressure vessel shall be based on computations that are determined using the latest
applicable edition of the ASME Code or the construction code to which the vessel was built. The resulting MAWP from these
computations shall not be greater than the original MAWP unless a rerating is performed in accordance with 8.2.
7.3.2 Computations may be made only if the following essential details comply with the applicable requirements of the code
being used: head, shell, and nozzle reinforcement designs; material specifications; allowable stresses; weld efficiencies; inspec-
tion acceptance criteria; and cyclical service requirements.
7.3.3 In corrosive service, the wall thickness used in these computations shall be the actual thickness as determined by inspec-
tion (see 5.6.2) minus twice the estimated corrosion loss before the date of the next inspection, as defined by:
t = tactual- 2 (Crate X linternaD
where
Crate governing corrosion rate in in. (mm) per year.
linternal = interval of the next internal or on-stream inspection in years.
tactual = the actual thickness of a CML, in in. (mm), measured during the most recent inspection.
7.3.4 If the actual thickness determined by inspection is greater than the thickness reported in the material test report or the
manufacturer's data report, it must be confirmed by multiple thickness measurements, taken at areas where the thickness of the
component in question was most likely affected by the thinning due to forming. The thickness measurement procedure shall be
approved by the inspector. Allowance shall be made for other loads in accordance with the applicable provisions of the ASME
Code.
7.4 Fitness For Service Analysis Of Corroded Regions
7.4.1 General
The actual thickness and maximum corrosion rate for any part of a vessel can be adjusted at any inspection considering the fol-
lowing:
7.4.2 Evaluation of Locally Thinned Areas
[Link] For a corroded area of considerable size the wall thicknesses may be averaged over a length not exceeding the follow-
ing:
For vessels with inside diameters less than or equal to 60 in. (150 cm), one-half the vessel diameter or 20 in. (50 cm), whichever
is less.
For vessels with inside diameters greater than 60 in. (150 cm), one-third the vessel diameter or 40 in. (100 cm), whichever is less.
[Link] Along the designated length, the thickness readings should be equally spaced. For areas of considerable size, multiple
lines in the corroded area may have to be evaluated to determine which length has the lowest average thickness.