API Inspectors Toolbox EE - User Guide

© Technical Toolboxes, Inc., 2010

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API Inspector Toolbox - Enterprise Edition User Manual

© Technical Toolboxes Inc., 2010


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Table of Contents INTRODUCTION Pg 7 Design Codes Pg 8 File Cabinet Pg 9 Engineering Data Pg 11 AST Calculations Pg 12 Shell Calculations Pg 13 Shell VDP (Variable Design Point) Calculations Pg 15 Appendix M Evaluation Pg 17 Appendix V Evaluation Pg 21 Appendix F Evaluation Pg 23 Atmospheric Roof Calculation Pg 25 Floor MRT Calculation Pg 27 Shell Settlement Survey Calculation Pg 30 Bottom Edge Settlement Evaluation Pg 32 Floor Bulge/Depression Evaluation Pg 35 AST Seal Inspection Pg 37 Nozzle Reinforcement Evaluation Pg 40 AST Venting Calculations Pg 41 Wind Loads Pg 45 Horizontal Tank Calculations Pg 47 Fillet Welded Patch Calculation Pg 50 Component Remaining Life Pg 53 Engineering Calculations Pg 55 PV Calculation Menu Pg 59 PV Calculations General Instructions Pg 60 Cylindrical Shell Calculations Pg 64 Spherical Shell Calculations Pg 69 Conical Shell Calculations Pg 72 Braced Surfaces Calculations Pg 72 Dimpled Jacket Calculation Pg 72 Half Pipe Jacket Calculation Pg 73 Formed Heads Calculation (Ellip, Tori. and Hemi.) Pg 75 Head Data Pg 80 Toriconical Head Calculations Pg 80 Flat Head Calculations Pg 81 Flat Non Round Cover Calculations Pg 83 Nozzle Calculations Pg 84 App 2 Flange Calculations Pg 85 Stnd Flanges Pg 86 Bolting Pg 88 Tube Calculations Pg 89 Tube Sheet Calculations Pg 92 Floating Cover Calculations Pg 93 Horizontal Tank Calculations Pg 94


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Tower Load Calculations Pg 94 Fillet Welded Patch Calculations Pg 96 Expansion Joint Evaluation Pg 96 MDMT Evaluation Pg 97 API-510 Remaining Life Calculation Pg 97 Engineering Calculations Pg 97 Rerate Cover Page Pg 98 Pipe Calculation Menu Pg 99 Pipe Calculations General Instructions Pg 99 Pressure Calculations Pg 100 Pipe Support Calculations Pg 102 Branch Reinforcement Calculations Pg 104 Blind Flanges Calculations Pg 105 App 2 Flange Calculations Pg 106 Pipe Standards Pg 107 Bolting Pg 107 Fillet Welded Patch Calculations Pg 107 Expansion Joint Evaluation Pg 107 API-570 Remaining Life Calculation Pg 107 Conversions Pg 108 Engineering Calculations Pg 108 Material Specifications Pg 109 Weld Rods Pg 111 Modulus of Elasticity Pg 112 Thermal Coefficient of Expansion Pg 113 Product Data (i.e. SG) Pg 114 Pipe Standards Pg 115 Class Ratings and Flange Sizes Pg 117 Class Ratings Pg 118 Weld Neck (WN) Flange Data Pg 119 Long Weld Neck (LWN) Flange Data Pg 120 Carbon Steel (CS) Pipe Size Data Pg 121 Stainless Steel (SS) Pipe Size Data Pg 121 Aluminum (Alum) Pipe Size Data Pg 122 Practical Minimum Thickness (tmin) Data Pg 123 Pipe Stress Tables Pg 126 Bolting Data Pg 128 Gasket Data Pg 129 Insulation Pg 131 Flange Weight Pg 132 Valve Weight Pg 133 Pipe Specs Pg 134 Tube Gage Size Pg 135 MDMT Pg 137 PWHT Pg 139


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Definitions Pg 140 Coatings Pg 141 Sheet Metal Data Pg 142 Process Specs Pg 143 API 653 AST Inspection Module Pg 144 Repair Specifications Pg 147

1. General 2. Nozzle Installation, 3. Repad Installation 4. Nozzle Removal 5. Shell Insert, 6. Lap Patch 7. Shell Attachment 8. Support Pads 9. Weld Repairs/Weld Overlay 10. Liner Inst/Repair 11. NDE Forms

Inspection Forms (Field Forms) Pg 149

1. Checklists: A. API C-1 In-Service Inspection Checklist, B. API C-2 Out-of-Service Inspection Checklist C. STI Inspection Checklist

2. CML Field Data Collection Sheets (Components and Nozzles): 3. Shell layout Coordinates Data Sheet: 4. Seal Inspection Field Data Sheet: 5. Shell Settlement Survey Field Data Sheet: 6. NDE Field Data Sheet: (Hydro Test form, MT Exam Form, PT Exam Form) 6. AST Repair Hold Point

A. Floor, B. Shell, C. Roof

AST Hydrostatic (Hydro) Test Calculations Pg 154 API 653 Inspection Report Builder Pg 157 Export/Import Reports Pg 159 Report Config / Appendix Pg 161 Report Component CML Record Pg 163 Report Nozzle CML Record Pg 165 Report Nozzle Calculations Pg 167 Report Shell Calculations Pg 170 Report Roof Calculations Pg 172 Report Floor MRT Calculations Pg 174 Report Shell Settlement Survey Calculations Pg 177 Report Write-up & Recommendations (Exec. Summary) Pg 179


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Report Check List Pg 181 Report NDE MT/PT Records Pg 173 Report Shell AutoCAD Inspection Drawings Pg 185 Report Roof/Floor AutoCAD Inspection Drawings Pg 192 Report Inspection Photographs Pg 198 API 510 PV Inspection Module Pg 200 Engineering Data Pg 203 Repair Specifications Pg 203 Welding Pg 203 Inspection Forms (Field Forms) Pg 206

1. API 510 Checklist 2. PV CML Field Data Collection Sheets 3. PV Boiler Plate Templates Dwg 4. NDE Field Data Sheet: (Hydro Test form, MT Exam Form, PT Exam Form)

AST Hydrostatic (Hydro) Test Calculations Pg 208 API-510 PV Inspection Report Builder Pg 211 Export/Import Reports Pg 215 Report Config / Appendix Pg 217 Report Component CML Record Pg 218 Report Cylindrical Shell Calculations Pg 222 Report Head Calculations Pg 229 Report Nozzle Calculations Pg 236 Report Write-up & Recommendations (Exec. Summary) Pg 238 Report Check List Pg 240 Report NDE MT/PT Records Pg 241 Report Supplementary Calculations Pg 241 Report AutoCAD Inspection Drawings Pg 241 Report Inspection Photographs Pg 243 API 570 Piping Inspection Module Pg 244 Engineering Data Pg 247 Repair Specifications Pg 247 Inspection Forms (Field Forms) Pg 247

1. API 570 Checklist 2. Pipe CML Field Data Collection Sheets 3. Pipe Iso Template Dwg 4. NDE Field Data Sheet: (Hydro Test form, MT Exam Form, PT Exam Form)

AST Hydrostatic (Hydro) Test Calculations Pg 251 API-570 PV Inspection Report Builder Pg 254 Export/Import Reports Pg 258 Report Config / Appendix Pg 260


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Report Component CML Record Pg 261 Report Pipe Calculations Pg 264 Report Write-up & Recommendations (Exec. Summary) Pg 266 Report Check List Pg 268 Report NDE MT/PT Records Pg 269 Report Supplementary Calculations Pg 269 Report AutoCAD Inspection Drawings Pg 269 Report Inspection Photographs Pg 270 Contacts Pg 271 Index Pg 272


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Introduction


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Design Codes

Figure DSN-1. Design Code Menu

The Design Code module aids in centralizing code files and saving access time. The “Design Code” is a module that allows users to save an Adobe Code file to a sub folder of the API Toolbox Program so that the link can be accessed from within the API Toolbox Program.

1) Open the Code File of interest (i.e. ASME Section I.pdf) and choose “Save as” 2) Open path to Inspectors Toolbox Program files (i.e., "C:\Technical Toolboxes, Inc\API 653 Inspectors Toolbox\"Codes) 3) Choose the file (ASME I.pdf) to “save as”. The Code module can be accessed from the Front Page, Report

Builder module and other modules. To access the code files from the front page, choose pull down icon “Design Codes” then click on Code Association such as ASME or API, then the Code of choice such as: ASME I, ASME II, ASME V, ASME VIII D1, ASME IX, API-510,

API-653, API-570, et


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File Cabinet

Figure FC-1. File Cabinet Selection

Users may want to develop documents in Word, Excel or Adobe for use in facilitating inspection or engineering projects or may already have files that are used often in association with API inspections or reliability engineering and may desire to access them via the API Toolbox Program during an MI evaluation. The File Cabinet aids in centralizing files and saving access time. The “File Cabinet” is a module that allows users to develop documents using existing Word, Excel and Adobe place holder files or to save a preexisting Word, Excel or Adobe file to a sub folder of the API Toolbox Program so that the link can be accessed from within the API Toolbox Program.

To develop a file in Word or Excel from the front page choose [File Cabinet] then click on one of the unused files (file 1, file 2 etc), use the existing linked document to write or produce the desired document. Enter document title in control form next to appropriate file no.

To replace the existing place holder document with the document of your choice.

1. Open the document of interest and choose “Save as”


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2. Open path to Inspectors Toolbox Program files (i.e., "C:\Technical Toolboxes, Inc\API 653 Inspectors Toolbox\MS Word Docs”)

3. Choose an unused file (i.e. File 1, File 2 etc.) to “save as” that associates with the placement you desire from the control form.

4. Enter Document Title in control form next to associated File No in the File Cabinet form.


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Engineering Data

Figure ED-1. Engineering Data Selection

The Engineering Data module can be accessed from the Front

Page, Report Builder module and other modules. To access the Engineering Data from the front page choose [Engineering Data] then click on file of choice (AST Calculations, PV Calculations, Pipe Calculations, Material Spec, Piping Standards, Product Data, et.)


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AST Calculations Menu

Figure ED-AST-1. AST Calculations Menu

The AST Calculations module can be accessed from the Front Page, Report Builder module and other modules. To access the AST Calculations, from the front page choose [Engineering Data] then click [AST Calculations] then choose from list of calculations.


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Shell Calculations (Vertical ASTs)

Figure ED- AST-2. Shell Calculation Data Entry Form

The Shell Calculations can be accessed from the Front Page, Report Builder module and other modules. To access the Shell Calculations from the front page choose [Engineering Data] then click [AST Calculations] and then choose [Shell Calculations] from list of available calculations.

Begin performing Shell Calculations by clicking the [+] icon at the top right hand corner and entering data in cells as called for.

Variable definitions are given in the table at bottom right and can be

accessed via the pull down menu. Click in the definition box and use vertical scroll to read all text.


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The fill height value is normally the tank height but may be decreased if the remaining life or tmin value is not acceptable for any of the courses. If that is the case, the fill height and governing course should be noted in the note section provided at the bottom.

Anytime a pull down selection is used, click the [Refresh] button to update form information that is being pulled from external static tables such as the material selection.

The joint efficiency can be determined from table 4-2 in lower left hand corner.

The material selection accesses a material list from API-650 but other material may be entered. If a material not on the default list is used then the material stress will have to be entered via the yellow cell under [Alt S] next to the default stress (S) cell. Clicking on the [Alt S] button will access the programs material table which bases its property values on ASME Section 2 Part D. The user must select the material from the pull down which, once chosen, the form will automatically calculate the stress values to be used for the applicable courses in accordance with API-653. The user will then have to enter the resulting values into the associated cells. New material not on the list may be entered into the Materials form via the Engineering Data module from the front page to be available for use in the shell calculations forms and sub forms.

Where there are circumstances that require the use of an alternate tmin, (i.e. using the nominal minus the corrosion allowance to determine tmin) the user may enter that value in the yellow cell under Alt tmin. This value will override the calculated tmin.

“Crs H” is the measured height of the course of interest in feet (i.e. an eight foot course would be 8, do not use tick (‘) marks for feet, just enter the number (8)) as it is used to calculate H (Fill height minus all Crs H values below course of interest)

Age variable is a single number (i.e. 4, 10, 13, 20 etc.), and not a date.

Notes may be entered if necessary in the lower right hand corner. Notes will appear on the bottom of the second page of the calculation report.

Use the file selection pull down menu in the upper left hand corner to access a previous record.

A record may be deleted by clicking the red “ال” icon at the top right hand corner and confirming.

To print, click the print preview icon (page w/ magnifying glass) in upper right hand corner then select print from the preview page. NOTE: Click on save icon in upper right hand corner before selecting print preview.


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Shell VDP (Variable Design Point) Calculations

Use Shell VDP evaluation for tanks with diameters greater than 199 ft.

Figure ED-AST-3. Shell VDP Calculation Data Entry Form

The Shell VDP Calculations can be accessed from the Front Page,

Report Builder module and other modules. To access the Shell VDP Calculations from the front page, choose [Engineering Data] then click [Calculations] and then choose [Shell VDP Calculations] from list of available calculations.

Begin performing Shell Calculations by clicking the [+] icon at the top right hand corner and entering data in cells as called for.

Variable definitions are given in table at bottom right and can be

accessed via the pull down menu. Click in the definition box and use


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vertical scroll to read all text. The report variable definitions may be accessed and edited for updates via the button in the top right hand corner.

The fill height value is normally the tank height but may be decreased if the remaining life or tmin value is not acceptable for any of the courses. If that is the case, the fill height and governing course should be noted in the note section provided at the bottom.


The joint efficiency can be determined from table 4-2 in the lower left hand corner.

The material selection accesses a material list from API-650 but other material may be entered. If a material not on the default list is used then the material stress will have to be entered via the yellow cell under [Alt S] next to the default stress (S) cell. Clicking on the [Alt S] button accesses the programs material table which bases its property values on ASME Section 2 Part D. The user must select the material from the pull down which, once chosen, the form will automatically calculate the stress values to be used for the applicable courses in accordance with API-653. The user will then have to enter the resulting values into the associated cells. New material not on the list may be entered into the Materials form via the Engineering Data module from the front page to be available for use in the shell calculations forms and sub forms.


“Crs H” is the measured height the course of interest in feet (i.e. an eight foot course would be 8, do not use tick (‘) marks for feet, just enter the number (8)) and is used to calculate H (Fill height minus all Crs H values below course of interest)

Age variable is a single number (i.e. 4, 10, 13, 20 etc.), not a date Notes may be entered if necessary in the lower right hand corner.

Notes will appear on the bottom of the second page of the calculation report.



To print, click the print preview icon (page w/ magnifying glass) in upper right hand corner then select print form the preview page. NOTE: Click on save icon in upper right hand corner before selecting print preview.


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Appendix M Evaluation Use Appendix M evaluation for tanks operating above 200°F.

Figure ED-AST-4. Appendix M Evaluation Data Entry Form

The Appendix M Evaluation can be accessed from the Front Page, Report Builder module and other modules. To access the Appendix M Evaluation from the front page, choose [Engineering Data] then click [Calculations] and then choose [Appendix M Evaluation] from list of available calculations.

Begin performing calculations by clicking the [+] icon at the top right hand corner and entering data in cells as called for.


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Variable definitions are given in table at bottom right and can be accessed via the pull down menu. Click in the definition box and use vertical scroll to read all text.

Use the vertical scroll to right as data is entered to access all data cells

Ambient Temperature should default to 65°F but can have a user value entered if desired.

The Service Condition (upper right hand corner) must be determined and selected. This selection will dictate required information and extent of required actions in accordance with code requirements.

The material selection accesses a material list from API-650. Other material may not be entered.

The M-1 Ratio will be determined for each course based on the material strength and temperature (ensure Design Temperature value is inputted before proceeding). The material must be selected from the pull down list to populate the material, M-1 Value and stress values. Alternately (for reasons of determining an acceptable rerate temperature), Table M-1 to the right of the page can be used to determine this Ratio. For each course using Table M-1: STEP 1) determine the Design (or rerate) Temperature (yellow cell

at top of form) STEP 2) select the Material STEP 3) click refresh button. STEP 4) enter the resulting Ratio value related to the design

temperature and corresponding stress column from Table M-1 (in green field) into the formula variables “M-1 Ratio” cell (green field) in the course of interest. Repeat this process using Table M-1 for each course. The “select condition” can be toggled back and forth after all values

are entered to determine which case is the governing (more restrictive) condition which is normally the operating condition.

The "fill height value" is normally the tank height but may be decreased if the remaining life or tmin value is not acceptable for any of the courses. If that is the case, the fill height and governing course should be noted in the note section provided at the bottom.


The joint efficiency can be determined from table 4-2 in the lower left hand corner.

Result cells will display “Green” if all calculated tmin results are less than actual thickness. Result cells will display “Red” if any calculated tmin results are greater than actual thickness. Decreasing fill height value is recommended until all cells are green. Recommended fill heights are


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based on actual thickness and should be used as a guide to decreasing fill height if any of the results cells are red.

Figure ED-AST-5. Appendix M Evaluation Data Entry Form (con’t)

If Manway and/or Flush Clean Out evaluations are required, Tables 3-3 and 3-10 can be accessed by clicking the buttons to the left to aid in determining original thicknesses according to size and fill height per API-650.

“Crs H” is the measured height of product up the course of interest in feet (i.e. an eight foot course with product up to six and half feet would be 6.5, do not use tick (‘) marks for feet, just enter the number (6.5)) and is used to calculate H (Fill height minus all Crs H values below course of interest)

Year Built input is the year only (i.e. 1980), not a date. Notes may be entered if needed in the lower right hand corner. The

notes will appear on the bottom of the second page of the calculation report.




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Appendix V Evaluation

Use Appendix V evaluation for tanks operating in partial vacuum.

Figure ED-AST-6. Appendix V Evaluation Data Entry Form

The Appendix V Evaluation can be accessed from the Front Page, Report Builder module and other modules. To access the Appendix V Evaluation from the front page, choose [Engineering Data] then click [Calculations] and then choose [Appendix V Eval] from list of available calculations.

Begin performing Appendix V Evaluation by clicking the [+] icon at the top right hand corner and entering data in cells as called for.


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Variable definitions are given in table in upper right corner and can be accessed via the pull down menu. Click in the definition box and use vertical scroll to read all text.

Buttons are available to the user at the top of the page to access other basic engineering functions such as conversions, simple math equations for areas and volumes for common components such as cylinders, cones and box shapes for quick results when needed.

Enter yellow cells to overwrite default values when they do not reflect as built conditions. Default values may be used if unknown as they are conservative values. Using default values because actual values are unknown may cause the calculations to fail the tank in which case the user may have to make a field check to verify the as built condition.

Anytime a pull down selection is used, click the Refresh button to update form information that is being pulled from external static tables such as the material selection.

The H values required are for the greatest value between stiffened sections of the shell. This would be the entire shell for most Tanks (being unstiffened) except if there are stiffing rings in which case a determination must be made as to the governing section as stated above. Where there are stiffing rings, only those attributing portions of the shell course values (H and t) need to be entered. The calculation aims to evaluate the weakest section for buckling and governing minimum required thickness.

The joint efficiency can be determined from API-653 table 4-2. (can be found in any of the shell type calculations as well)

The material selection accesses a material list from API-650 but other material may be entered. If a material is used that is not on the default list, then the material stress will have to be entered via the yellow cell under Alt S next to the default stress (Sds) cell. New materials not on the list may be entered into the Materials form via the Engineering Data module from the front page to be available for use in the shell calculations forms and sub forms throughout the program.



A record may be deleted by clicking the red “ال” icon at the top right hand corner.



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Appendix F Evaluation

Use Appendix F evaluation for tanks operating at pressures above weight of roof plates but less that 2.5 psi.

Figure ED-AST-7. Appendix F Evaluation Data Entry Form

The Appendix F Evaluation can be accessed from the Front Page,

Report Builder module and other modules. To access the Appendix F Evaluation from the front page, choose [Engineering Data] then click [Calculations] and then choose [Appendix F Eval] from list of available calculations.

Begin performing Appendix F Evaluation by clicking the [+] icon at the top right hand corner and entering data in cells as called for.


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A [conversions] button is available to the user at the top right of the page.

Enter yellow cells to over write default values when they do not reflect as built conditions. Default values may be used if unknown as they are conservative values. Using default values because actual values are unknown may cause the calculations to fail the tank in which case the user may have to make a field check to verify as built condition.


Notes may be entered if necessary at the bottom of the data page. Notes will appear on the bottom of the second page of the calculation report.





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Atmospheric (ATM) Roof Calculation

Figure ED-AST-8. Atmospheric Roof Calculation Data Entry Form

The ATM Roof Calculations can be accessed from the Front Page,

Report Builder module and other modules. To access the ATM Roof Calculations from the front page, choose [Engineering Data] then click [Calculations] and then choose [ATM Roof Calc] from list of available calculations.

Begin performing ATM Roof Calculations by clicking the [+] icon at the top right hand corner and entering data in cells as called for.

Alternately, the user can select an existing file and click the

duplicate icon at the top right hand corner and update the data as required to reflect the new record.


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The user can enter alternate tmin value in yellow cell to over write calculated values.

Notes may be entered if necessary at the bottom of the data page. Notes will appear on the bottom of the page of the calculation report.




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Floor MRT Calculation

Figure ED-AST-9. Floor MRT Calculation Data Entry Form

The Floor MRT Calculation can be accessed from the Front Page,

Report Builder module and other modules. To access the Floor MRT Calculation from the front page, choose [Engineering Data] then click [Calculations] and then choose [Floor MRT] from list of available calculations.

Begin performing Floor MRT Calculation by clicking the [+] icon at the top right hand corner and entering data in cells as called for.

Variable definitions are given in table in upper right corner and can

be accessed via the pull down menu. Click in the definition box and use vertical scroll to read all text.


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Threshold setting for the MFE floor exam should be considered prior to getting started with the exam to determine a basis to start with. The client should be consulted to obtain information on the tank such as what previous inspections of the tank floor may have yielded. The variables may need to be adjusted as the inspection progresses based on predominant findings such as those listed in 1-6 below.

Determining RTbc and RTip thresholds depends on what the existing conditions for top and bottom side yields. The following are some guidelines to consider:

1. Overall, if the bottom is clean with virtually no “relevant” indications, consider, as a minimum, starting with 40mil material loss (i.e. 0.250” plate would = 0.210” threshold and therefore, RTbc would = 0.21”). Anything less than 40mil would be difficult for MFE technology to pick up in a favorable percentile and therefore is not practical to set the threshold any lower. Remember that just because no relevant indications were recorded doesn’t mean there weren’t any indications at all, just none that were above the threshold or “relevant” or in the red.

2. If the bottom side has just a few areas with significant indications and the top side has a numerous amount of indications, determine max allowable topside pitting that would be cost effective for repairs that would match well with the minimum for the bottom after the few areas are repaired (aim for 40mil material loss as in #1 for RTbc)

3. If the bottom side has numerous areas with significant indications and the top side has very few areas of indications, determine max allowable bottom side pitting that would be cost effective for repairs that would match well with the minimum for the top after the few areas are repaired (aim for 50 to 70mil material loss for top side pitting)

4. If the both sides have numerous areas with significant indications, determine max allowable top and bottom side pitting that would be cost effective for repairs.

5. If it is realized early on in the exam process that the damage is so severe that replacing the floor plates would be best and most cost effective option, address these issues with the client as soon as possible to deter any unnecessary inspections.

6. Always consider how adding coatings or CP systems will affect the results as well, if it is a viable alternative for the client.

7. For all scenarios, consider adjusting the Or (next inspection period) to limit scope of repairs, if it is a viable alternative for the client.


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Notes may be entered if necessary at the bottom right of the data

page. Notes will appear on the bottom of the calculation report. Use the file selection pull down menu in the upper left hand corner

to access a previous record. A record may be deleted by clicking the red “ال” icon at the top right

hand corner and confirming.



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Shell Settlement Survey Calculation

The Shell Settlement Survey Calculations can be accessed from the Front Page, Report Builder module and other modules. To access the Shell Settlement Survey Calculation from the front page, choose [Engineering Data] then click [Calculations] and then choose [Settlement Surv] from list of available calculations.

Shell Settlement Surveys should be performed utilizing the API Inspector Toolbox Settlement Survey Inspection Form accessed via the API-653 Module [Inspection Forms] button.

The preliminary form calculates survey points to even numbers to better fit a cosine curve.

The max distance between survey points is to be limited to 31.42 ft.

Begin performing Shell Settlement Survey Calculation by clicking

the [+] icon at the top right hand corner and entering data in cells as called for.

Using the field data form, enter the values for each point into the form.

Variable definitions are given above the data input cells for user convenience.

The program defaults to a MOE of 29,000,000. Click on the [E] button to the right of the variable definitions to access MOE values for diverse temperatures and material.

The "Feet" and "Inches" cells must have an entry in both. If measurements were taken in inches only, the "Feet" cell should have a "0" entered in to it. If measurements were taken in feet only, the "Inches" cell should have a "0" entered into it otherwise enter entries in both feet and inches (i.e., 5 (ft) and 2.5 (inches)) (no tick marks [ ' or " ])

Click on the [Calculation] button at the right of the data point cells. This button will calculate the settlement in accordance with the requirements of Appendix B and product a chart with the points plotted relative to a best fit cosine curve.

The optimum cosine curve must have a value of R^2 greater than 0.90 as set forth in the Appendix B criterion. If this check comes up less than that required it may be necessary to reshoot the settlement using more points.


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Figure ED-AST-10. Shell Settlement Survey Calculation Data Entry Form

Notes may be entered if necessary at the bottom of the data page.

Notes will appear on the bottom of the calculation report. Use the file selection pull down menu in the upper left hand corner

to access a previous record. A record may be deleted by clicking the red “ال” icon at the top right

hand corner and confirming.



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Bottom Edge Settlement Evaluation

Figure ED-AST-11. Bottom Edge Settlement Evaluation Data Entry Form

The Bottom Edge Settlement Evaluation can be accessed from the Front Page, Report Builder module and other modules. To access the Bottom Edge Settlement Evaluation from the front page, choose [Engineering Data] then click [Calculations] and then choose [Edge Settlement] from list of available calculations.

Begin performing Calculations by clicking the [+] icon at the top of form and begin entering data in cells as called for.


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Variable definitions are given in table at top right and can be accessed via the pull down menu. Click in the definition box and use vertical scroll to read all text.

Use the vertical scroll to right to as data is entered to access all data cells

Use [conversion] button at top to aid in converting field data units to form data units (i.e., feet to inches, inches to feet, etc.).

Weld to shell orientation (WO) (parallel, perpendicular or degree of angled) must be determine for each area of interest to be evaluated before entering data. See API-653 Appendix B Figure B-12—Edge Settlement with a Lap Weld at an Arbitrary Angle to the Shell.

Figure B-12—Edge Settlement with a Lap Weld at an Arbitrary Angle to the Shell

Enter values for M1, M2 and R based on field survey

measurements. The “Bmax” values are determined from API-653, Appendix B

Figure 10 and/or 11 based on tank diameter and R value in the area of interest. These values can be determined from the calculation table at the right of form. The values displayed are based on the diameter selected at top of page and the weld orientation (WO) selected (parallel [figure 10] or perpendicular [figure 11]). For each area of interest, determine where the R value falls to enter in the two possible cells (between values for R1 and R2 or between values for R3 and R4). Tanks less than 60’ diameters will only have one choice (between values for R3 and R4).

Example: Tank Dia. = 60’, WO= Parallel and R =3.4.

1) At top of Table select “Parallel”. 2) R value in the area of interest (i.e., Point 1) falls between

values for R3 and R4 therefore enter R value (in yellow cell from area of interest (point 1) into yellow cell between values for R3 and R4 in the table.

3) Enter results (2.91 in green cell just below the yellow cell) into the “Bmax” cell in the area of interest (point 1).


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4) See Notes 1 & 2 below table for Values that fall outside of table ranges.

5) Repeat steps 1-4 for each area of interest if evaluating more than one location.

In the case where the WO is angled to the shell the “Bmax” can be determined by using the calculation just under the tables that reads “Calculation for weld orientation at an angle (a)”. Determine values for both WO’s from figures 10 and 11 as given above and enter resulting “Bmax” values in to the cells provided (where “Be” = Parallel results and “Bew” = Perpendicular results). Enter Angle in cell designated “a”. Enter new “Bmax” result (green cell) into the “Bmax” data cell in area of interest.

If results in area of interest indicate “NDE Req.” or “Unsat” see General Notes 1 and 2 to the right of form for directives.

Anytime a pull down selection is used, click the [Refresh] button to update form information that is being pulled from external static tables such as figures 10 and 11.

Notes may be entered if necessary at the bottom. Notes will appear on the bottom of the second page of the calculation report.


A record may be deleted by clicking the red “ال” icon at the top right hand corner and then confirming the action.



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Floor Bulge/Depression Evaluation

Figure ED-AST-12. Floor Bulge/Depression Evaluation Data Entry Form

Applicable to bulges or depressions in floor plates near shell (<=2R) or bulges or depressions in floor plates remote from the shell where weld design is single pass lap welded.

The Floor Bulge/Depression Evaluation can be accessed from the Front Page, Report Builder module and other modules. To access the Floor Bulge/Depression Evaluation from the front page, choose [Engineering Data] then click [Calculations] and then choose [Floor Bulge] from list of available calculations.



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Variable definitions are given in notes at bottom. Use the [conversion] button at top to aid in converting field data units to

form data units (i.e., feet to inches, inches to feet, etc.). If results in area of interest indicate “Unsat” further evaluation should be

done by a storage tank engineer. Notes may be entered if necessary at the right of the form. Notes will

appear on the bottom of the second page of the calculation report. Use the file selection pull down menu in the upper left hand corner to

access a previous record. A record may be deleted by clicking the red “ال” icon at the top right hand

corner and then confirming the action.



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AST Seal Inspection

Figure ED-AST-13. Seal Inspection Data Entry Form

The criterion for this evaluation is from EPA REGULATIONS 40 CFR Chapter 1, Part 60.

The Seal Inspection Evaluation can be accessed from the Front Page, Report Builder module and other modules. To access the Seal Inspection Evaluation from the front page, choose [Engineering Data] then click [Calculations] and then choose [Seal Inspection] from list of available calculations.

The seal Inspection should be performed utilizing the API Inspector Toolbox Seal Inspection form accessed via the API-653 Module “Inspection Forms” button.

Begin performing calculations by clicking the [+] icon at the top of form and begin entering data in cells as called for.

Use [conversion] button at top to aid in converting field data units to form data units (i.e., feet to inches, inches to feet, etc.).


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Use vertical scroll on right to access all data entry cells as you progress

along entered data. Recommend entering value for "Eff. Length" as ½ the gap length to

determine square inches based on normal physical profiles where the gap starts from point “A” and gradually widens at an angle to its max width from the shell at point “B” then tapers back at an angle to point “C” on the other side. Theoretically, splitting the gap length at point “B” (in half) and folding back onto the remaining half would form a rectangle, therefore the square units (inches) can be determine from the width times half the length.

The program will evaluate gap tolerances and visual findings based on EPA regulations as reference above and tally all required repairs in table at bottom of page and display a “Due Date” if repairs are required. A brief of the EPA requirements can be found half way down the data from and on the report form.

The “#” column will display a “1” if the gap spacing is out of tolerance. Next Inspection and Repair dates will be based on EPA regulation

criterion and key off the inspection dates entered at top of the form. Notes may be entered if necessary at the right of the form. Notes will



corner and then confirming the action.


Click on “W” icon at top of form to save completed inspection document in

a Word File format and the “Mail” icon to email document if desired.


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Nozzle Reinforcement Evaluation

Figure ED-AST-14. Nozzle Reinforcement Evaluation Data Entry Form

The Nozzle Reinforcement Evaluation can be accessed from the Front Page, Report Builder module and other modules. To access the Nozzle Reinforcement Evaluation from the front page choose [Engineering Data] then click [Calculations] and then choose [Noz Reinf.] from list of available calculations.

Begin performing Nozzle Reinforcement Calculations by clicking the [+] icon at the top right hand corner and entering data in cells as called for.


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Anytime a pull down selection is used for data entry click the [Refresh] button to update form information that is being pulled from external static tables such as the material selection.

The material selection accesses a material list from API-650 and ASME B31.3. No other material may be entered.

Click the [Rprt Def.] button at top of page to view and or edit variable definitions that will be included in the report.

Clicking the “Noz Sch” button in the Nozzle Data section will access the pipe size data for the specified pipe size as long as the size is from the pick list. If the size is not from the list then it will be blank. The selection button to select another size does not work in this mode.

tr and trn values require separate calculations and should be determined prior to this evaluation.

Notes may be entered if necessary in the middle of the form. Notes will appear on the bottom of the first page of the calculation report.





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AST Venting Calculations

Figure ED-AST-15. AST Venting Calculation Data Entry Form

The AST Venting Calculations can be accessed from the Front Page, Report Builder module and other modules. To access the AST Venting Calculations from the front page choose [Engineering Data] then click [Calculations] and then choose [AST Venting] from list of available calculations.

Begin performing AST Venting Calculations by clicking the [+] icon at the top right hand corner and entering data in cells as called for.

Variable definitions are given in table at lower left hand corner and can be

accessed via the pull down menu. Click in the definition box and use vertical scroll to read all text. (Always be aware of the units each variable is requiring).

Ensure Capacity enter in upper left corner is in Barrels (not Gallons).


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If the product is not in the pull down list then it can be entered (typed in). New product MSDS info and specification entry (i.e. M value, L value, flash point, boiling point, et.) can be entered for use in the program via the [*] button next to the stored product options pull down. It may not show up on the list until next time the calculation is open.

Where Latent Heat of Vaporization is unknown, use 50 BTU's per pound for conservative value. (Enter a value via the [*] button next to the stored product options pull down.)

Where the M variable is unknown, use 25 g/mol for a conservative value. (Enter value via the [*] button next to the stored product options pull down.)

Anytime a pull down selection is used for data entry click the [Refresh] button to update form information that is being pulled from external static tables such as the material selection.

A work sheet in lower right hand corner is available to aid in the determining Design Pressure, Pt and Pa values (always be aware of the units each variable is requiring). Normally, if the design pressure is unknown the weight of the roof plate in the corroded condition is assumed to be the design pressure. If the roof has a PV Vent, then the PV Vent setting will govern the design pressure. If the tank falls under the Appendix F criteria for tanks with small internal pressures, then calculations in accordance with appendix F must be performed to determine allowable internal pressures.

All resulting ratios should be less than 1. Results that are out of the capacity requirements in this evaluation will be displayed with a red background with text advising those results.

A tank with a frangible roof-to-shell attachment, as described in API Standard 650, does not require emergency venting devices therefore no evaluation is need for emergency venting.


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Figure ED-AST-16. AST Venting Calculation Data Entry Form (con’t)

The emergency venting calculation includes the normal venting capacity and therefore data that was previously entered in the normal venting out breathing calculation is not required to be re-entered in the emergency venting calculation.

Additionally, out breathing does not normally include normal operational flows of inerting systems (i.e. nitrogen blankets) except if the failure of the regulator would cause an over pressure condition.

Additional inbreathing may include other product draws or water draining that could possibly happen simultaneous with normal product issuing operations.

Notes may be entered if necessary in the middle of the form after the Normal venting calcs and at the bottom after the Emergency venting calcs. Notes will appear at the bottom of the first and second page, respectively, of the calculation report.




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Page 46

Wind Load Evaluation

Figure ED-AST-17. Wind Loads Data Entry Form

The AST Wind Loads Evaluation can be accessed from the Front

Page, Report Builder module and other modules. To access the AST Wind Loads Evaluation from the front page, choose [Engineering Data] then click [AST Calculations] and then choose [Wind Loads] from list of available calculations.

Begin performing Wind Loads Evaluation by clicking the [+] icon at the top right hand corner and entering data in cells as called for.

Variable definitions are given in table in upper right corner and can

be accessed via the pull down menu. Click in the definition box and use vertical scroll to read all text.


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Enter yellow cells to over write default values when they do not reflect as built conditions. Default values may be used if unknown as they are conservative values. Using default values because actual values are unknown may cause the calculations to fail the tank in which case the user may have to make a field check to verify as built condition.


The dome radius need only be selected if the roof is of a dome design otherwise leave blank

If select "Unknown" from the list of materials if the construction material is unknown.

There are pick buttons for determining Insulation weight and local wind speeds.

Notes may be entered if necessary at the bottom of the data page. Notes will appear on the bottom of the second page of the calculation report.



To print, click the print preview icon (page w/ magnifying glass at the top of the form then select print from the preview page. NOTE: Click on save icon in upper right hand corner before selecting print preview.


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Horizontal Tank Calculations

Figure ED-AST-18. Horizontal Tank Calculation Data Entry Form

The Horizontal Tank Calculations can be accessed from the Front Page, Report Builder module and other modules. To access the Horizontal Tank Calculations from the front page choose [Engineering Data] then click [Calculations] and then choose [Horizontal Tank Evaluation] from list of available calculations.

Begin performing Horizontal Tank Calculations by clicking the [+] icon at the top right hand corner and entering data in cells as called for.

Variable definitions are given in table at top and can be accessed via the

pull down menu. Click in the definition box and use vertical scroll to read all text. Year Built entry is the year only (YYYY) (i.e. 1985), not a full date


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The fill height (FH) value is normally the tank height (in inches) but may be decreased if the remaining life or tmin value is not acceptable. If that is the case, the fill height should be noted in the note section provided at the bottom.


The “Nom Dia.” selection refers to the nominal diameter of the heads in inches and is the determining factor for selecting the head volume used in the product weight calculation. If the shell diameter is an off size from the listing, choose the next larger diameter for conservative estimate.

Use the [Head Data] button to determine the material weight (Mtl #) of the heads. Enter values for 1 head only, the formula calculates X2

In the “Other Weight” cell, include the aggregate weight of any nozzles, catwalks, pipe supports, agitators or other connecting appurtenances that would come to bear on the tank

Where the angle (a°) is of an off value, use a lesser angle for a

conservative evaluation or use the interpolation table at top right and insert resulting “K” values in the “User Defined” (yellow) cells below the K value cells (K1, K2, et). See step (4) under the CIRCUMFERENTIAL STRESS paragraph below for example of using an interpolation table.

The material selection accesses a limited material list based on data from ASME Section 2 Part D but other material may be entered. If a material not on the default list is used then the material stress will have to be entered via the yellow cell under “User Defined” under the default stress cell. Clicking on the [Material Spec] button will accesses the programs material table. The user must select the material from the pull down which, once chosen, the form will automatically fill in the stress values. New material not on the list may be entered into the Materials form via the Engineering Data module from the front page to be available for use in the shell calculations forms and sub forms.

Stress values (S) defaults to stresses at temperature. Modulus of Elasticity material values (ME) defaults to stresses at ambient temperature therefore, always check stress values at temperature and enter corrected value in user defined cells. Clicking on the [Material Spec] button will access stress data for the material selected and clicking on the [ME] button will access the modulus of elasticity values where you will have to select the material type and determine the value at temperature. Values are times 10^-6 (29.5 = 29,500,000 PSI)


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Stress values (S) defaults to stresses at temperature. Modulus of Elasticity material values (ME) defaults to stresses at ambient temperature therefore, always check stress values at temperature and enter corrected value in user defined cells. Clicking on the [Material Spec] button will access stress data for the material selected and clicking on the [ME] button will access the modulus of elasticity values where you will have to select the material type and determine the value at temperature. Values are times 10^-6 (29.5 = 29,500,000 PSI)

The CIRCUMFERENTIAL STRESS calculation at the bottom of the form must have the K6 value for the horn of the saddle and wear plate (if it extends beyond the horn of the saddle) determined using the table provided just above the calculation entries.

1) Choose the angle for the horn of the saddle (a°) and click the [Refresh] button at the top. NOTE: Where the angle (a°) is of an off value but within an inch or two, use a lesser angle for a conservative evaluation otherwise use the interpolation table to the right and insert resulting “K6” values in the associated cell.

2) When applicable, (using the same K6 table) choose the angle for the horn of the wear plate (a°) and click the [Refresh] button at the top. NOTE: Where the angle (a°) is of an off value but within an inch or two, use a lesser angle for a conservative evaluation otherwise use the interpolation table to the right and insert resulting “K6” values in the associated cell.

3) Ratio's < 0.500 use K6 value for 0.500, Ratio's >1.05 use K6 value for 1.05

4) Using the K6 Interpolation Table: a. Angles (a°) of subject of interest (saddle or wear

plate horn) will default to previously enter value as will the values relative to where (a°) falls in between. (i.e 122° for the saddle)

b. Using the K6 table, choose the next lesser angle (a°) (i.e 120°) and click the [Refresh] button at the top.

c. Enter the angle and the resulting K6 value into the associated cells in the Interpolation Table (to the left) (i.e a°=120° and K6 = 0.053)

d. Using the K6 table, choose the next greater angle (a°) (i.e 130°) and click the [Refresh] button at the top.

e. Enter the angle and the resulting K6 value into the associated cells in the Interpolation Table (to the right) (i.e a°=130° and K6 = 0.045)


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f. Enter the resulting K6 value (0.0514) under the middle a° (122) value into the associated K6 cells in the evaluation of interest (saddle or wear plate). (click on button [Input value] to automatically enter that value).

Values that are not acceptable will show in a “Red” cell. Overstressed

components may require iteration of the shell tmin value (ts) or fill height (FH) value to bring tank into acceptable operating parameters and any restrictions addressed in the note section.

Notes may be entered if necessary at the bottom. Notes will appear on the bottom of the second page of the calculation report.





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Fillet Welded Patch Calculation

Figure ED-AST-19. Fillet Welded Patch Calculation Data Entry Form

The Fillet Welded Patch Calculations can be accessed from the Front Page, Report Builder module and other modules. To access the Fillet Welded Patch Calculations from the front page, choose [Engineering Data] then click [Calculations] and then choose [Patch Calc] from list of available calculations.


Variable definitions are given in text next to variable. Stress values default to Stress Value for material at temperature for year

built in accordance with ASME Section 2 part D. Always confirm stress at temperature and consider options for material stress for latest code edition (click


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the [98 S Value] for vessel built before 1999 or [00 S Value] for vessel built after 1999 to verify stress at temperature).

Material stress values default to ASME Section 2 part D. These values may be over ridden if other values are to be use (i.e. B31.3 Table A for piping or API-650 Material Stress values for Storage tanks)

If results in Patch Dimensions section indicate “NOT ALLOWED”, then patch thickness may need to be reduced.

If results in Stress indicate “NOT ALLOWED”, then patch may have too large an area and may need to be reduced in dimensions or if that is not an option, consider permanent repair in lue of patch plate.

Notes may be entered if necessary at the right of the form. Notes will appear on the bottom of the second page of the calculation report.





Page 54

Component Remaining Life Calculation

Figure ED-AST-20. Component Remaining Life Calculation Data Entry Form

The Component Remaining Life Calculations can be accessed from the Front Page, Report Builder module and other modules. To access the Component Remaining Life Calculations from the front page, choose [Engineering Data] then click [Calculations] and then choose [Comp Life Calcs] from list of available calculations.


For Variable Definitions click [Variable Def] button at the top right of form.

Definitions are given in the table that pops up and can be accessed via the pull down menu. Click in the definition box and use vertical scroll to read all text.


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The Reference Calculation Table is for common component calculations and does not show in report. The user is to make a selection for the type of component in upper right of table. Minimum thickness “t” results will appear in related cell in accordance with selection.

Use upper drop down selection for pipe material (for B31.3 Table A material stress) and Use lower drop down selection for Pressure Vessel Material (for ASME Sect. 2 Part D material stress).

Always confirm stress at temperature and consider options for material stress for latest code edition by clicking the [SPp] (for pipe stresses) or [SPv] )for pressure vessel) buttons to verify stress at temperature.

Begin entering component data in the existing data cells in the form sub section. To enter another component click the [+] icon or select the Duplicate Icon in the component data sub section (not at time of page).

Pick the CML of interest and click [NPS per CML] to reference pipe sizes

to determine nominal (original or previous) thickness of pipe or nozzle components. The form will pop up and display the data related to size entered in the “Size” cell for that CML. The form will be empty if the size is not a size found in the table.

Reference tables for minimum thicknesses (tmins) for pipe and pressure vessels can be found at the bottom of the form.


Notes may be entered if necessary at the right of the form. Notes will appear on the bottom of the second page of the calculation report.




Page 56

Engineering Calculation

Figure ED-AST-21. Engineering Calculation Data Entry Form

The Engineering Calculations can be accessed from the Front Page, Report Builder module and other modules. To access the Engineering Calculations from the front page, choose [Engineering Data] then click [Calculations] and then choose [Eng. Calcs] from list of available calculations.

Begin performing Calculations by entering data in cells as called for and clicking [calc] button. This calculation form does not record data therefore all data will be loss when exiting form.

Variable definitions are found in text next to variable. Use [Conversion] button at top to aid in converting field data units to form

data units (i.e., feet to inches, inches to feet, etc.).


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Figure ED-AST-22. Conversions Data Entry Form

The [Component Combined Weight Calcs] button directs the user to a form for estimating weight of a vessel considering all components. This form does record data for future access.


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Figure ED-AST-23. Component Combined Weight Calcs Data Entry Form

Begin performing these calculations by clicking the [+] icon at the top of

form and begin entering data in cells as called for.

Reference various component/object Tables via buttons scattered

throughout form (next to applicable variable). Notes may be entered if necessary at the right of the form. Notes will



corner and confirming.


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Page 60

PV Calculations Menu

Figure ED-PV-1. Calculations Menu

The Calculations module can be accessed from the Front Page, Report Builder module and other modules. To access the Calculations, from the front page choose [Engineering Data] then click [PV Calculations] then choose from list of calculations.


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PV Calculations General Instructions

Begin performing these calculations by clicking the [+] icon at the top of form and begin entering data in cells as called for.

Variable definitions are given in table at right and can be accessed via the pull down menu. Click in the definition box and use vertical scroll to read all text.

Anytime a pull down selection is used and opening, click the [Refresh] button to update form information that is being pulled from external static tables such as the material selection.

User defined cells (yellow cells adjacent to or below related cell) are provided to allow the user the option to overwrite certain variables when necessary.

Material Selection - The material selection accesses a material list based ASME Section 2 Part D stress values but other material may be entered. Select the material of interest from the pull down menu (the pull down menu must be used in order to auto populate the stress (S) value). If a material not on the default list is used then you can ether enter in the new material in the (Material-Grade) cell and the associated material stress value can be entered in under the default stress (S) cell or you can enter the material and associate specifications into the materials module via the [Engineering Data]/[Material]/[Add/Edit] buttons.

Stress (S) Values - Clicking on the [98 S] or [00 S] button will access the programs material stress sub tables which base its property values on ASME Sect 2 Part D. The [98 S] button will access the 4x safety factor stress used to design pressure vessels before 1999. The [00 S] will access the 3.5x safety factor stress values used to design pressure vessels after the change in the ASME 1999 addenda. (user should use the stress value used in the design of the vessel as referenced on the Mfg U1 data sheet). User must note the material “S” associated with the design temperatures. NOTE 1: the “S” value will default to the stress values at temperature of

material selected for the year the vessel was built but may be overwritten by a user defined stress value if different from the default “S” Variable.

NOTE 2: API-510 allows the use of the most current code values for use in corrosion calculations, therefore, if a vessel tmin or remaining life value results in limited or expired remaining life based on the original “S” values concluded from the “98 S” tables the user may alternately use the “00 S” value at temperature to gain some operating time on the vessel if the vessel meets the criteria of API-510 7.3 and Figure 8-1 for rerating.


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The Joint Efficiency (E) can be determined from the U1 data sheet or the

vessel nameplate. The [Table 12] button below the first calculation is available to assist in determining the “E” value based on configuration and degree of RT. Also user can refer to the program API-510 Insp. Module base page and click on the [Welding] button at the bottom for more specific details of code requirements for determining joint efficiencies. External Pressure Charts (X-Chart) - Follow these instructions for use of the X-Charts when referenced in a PV Calculation.

Figure ED-PV-2. External Chart (X-Chart) - Figure CS-2 Step 1) Determine value A . The Value for variable A is determined from X-Chart – Figure G (1 or 2) using the resulting L/Do and Do/t ratio values.

a. Click on the [X-Chart] button below the calculation b. Looking at the left side Y axis of the Figure G Chart, determine

which chart to use (tab one or two) based on the L/Do value. c. From that point (where L/Do value lands on the Y axis) move to the

right in a straight line across the grid to the intersection of the


Page 63

applicable Do/t line (or approximate location of an intermediate line between given values).

d. From that point move in a straight line down to the values given along the chart horizontal axis and note that value (value A).

e. Close out the X-Charts and enter that resulting value in the A cell.

Note: Alternately, for CS material with X-Chart designations of Figure CS-2 there is a table with tabulated values to the right of the formula that may be used to determine the value of A.

Step 2) Determine value B (or E) . The Value for variable B is determined from the applicable material X-Chart (i.e. Figure CS-1, CS-2, HA-1, et.) and shown in the X-Chart cell above the calculation in the calculation of interest that reference these instructions. Using the resulting A value from above,

a. Click on the [X-Chart] button below the calculation and click on the associated X-Chart TAB (i.e. Fig. CS-1, Fig. CS-2, Fig. HA-1, et). If the referencing X-Chart is not available in the TAB options then user must reference ASME Section II Part D, normally these X-Charts are found in the back pages of that Code.)

b. Looking at the bottom X axis of the applicable X-Chart, locate the A value.

i. If A falls to the right of the associated material/temp line at the point where it intersects with the X axis;

1. come up in a straight line from where A falls on the X axis to the intersection of the temperature line for which the vessel was design for or approximate location of an intermediate temperature line between given values.

2. From that point move in straight line across to the values given along the applicable X-Chart right side Y axis and note that value (value B).

3. Close out the X-Charts and enter that resulting value in the B cell. NOTE: Alternately, for CS material with X-Chart designations of CS-2 there is a Table with Tabulated Values to the right of the formula.

ii. If A falls to the left of the associated material/temp line;

1. Close out the X-Chart forms 2. Click on the [MOE] button below the

calculations.


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3. Select the material type 4. Note the value at temperature (these value

are in PSI x 10^6 (Millions of PSI) where 28.5 would be entered into the E cell as “28500000”)

5. Enter the resulting value into the “B or E” cell





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PV Cylindrical Shell Calculations

Figure ED-PV-3. Cylindrical Shell Calculations

To access the Cylindrical Shell Calculations page from the front page, choose [Engineering Data] then click [PV Calculations] then choose [Cylindrical Shell]. This page can be accessed from the Report Builder as well.

Reference PV Calculation General Instructions at the start of the PV Calculations Section of this instruction manual to begin performing these calculations.

The Static Height (SH) value is normally the tank liquid operating level height (in feet) from the bottom shell weld of a vertical vessel (or bottom of corroded area of interest where localized corrosion is being evaluated), if the vessel has a liquid operating level. If the vessel is used in gaseous service the SH value is “0”. Horizontal vessels “SH” would be the height (in feet) from the bottom most elevation up to the operating liquid level along an axis in the center cord of the cylinder cross section. Enter the Specific Gravity (SG) of product. If unknown use 1.00.



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Figure ED-PV-4. Liquid Level for Static Head (SH) Determination

For Material Selection, Stress (S) Values, and Joint Efficiency (E) Reference PV Calculation General Instructions at the start of the PV Calculation Section of this instruction manual for instructions.

. External Minimum Thickness Calculations: Vessels that are rated for full vacuum (denoted on the U1 for as FV in the

MAWP line) should have a value of 15 entered into the “Design PA” (normal atmospheric pressure is 29.9 wc (inches of Water Column) which equals to 14.7 psi and therefore a full vacuum would produce 14.7psi (rounded to 15 psi) of external pressure on the vessel.

The “Design Pa” considers to the sum of Design Internal Vacuum (ext. psi) + Jacket MAWP (psi).

Calculating minimum thickness requirements for external pressures for cylindrical type components i.a.w. ASME Section VIII, Division 1, requires making several iterations using estimated thicknesses and solving for Pa (pressure) referencing external pressure charts (X-Charts). as follows:

1) Determine value L where L = the most critical length (the longest unsupported span) between lines of support along the longitudinal axis of a cylindrical component (i.e. Shell, Nozzle, Boot, et.). Lines of support include any point along the vessel shell that gives it inherent strength (addition strength in the girth) to resist collapsing such Compression rings, Flanges, Jacket tie-ins and includes 1/3 of the vessel heads measure from the head tangent as illustrated below in Figure ED-PV-4


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Figure ED-PV-5. Length L Determination

2) Determine starting value t where t = the minimum thickness (tmin) for

the vessel part under consideration required to resist external pressures. This t value should start with the tmin required for internal pressures (where E=1) as this value cannot be less than that required for internal pressure.

3) Applicable X-Chart - The Applicable X-Chart will populate the X-Chart Cell based on the material chosen. The user has the option of viewing the material data form to verify information associated with that material. Click on [Material] button below the calculation (if error message pop ups click [refresh] button and retry). This will bring up the related material spec from which the user must note the applicable X-Chart (to the right of the spec. form). The referenced X-Chart can be overwritten by inputting new Figure ID in the user defined cell below the default cell. 4) For determining A and B (E) Values, Reference PV Calculation General Instructions at the start of the PV Calculations Section of this instruction manual for instructions on using the X-Charts (Fig G, CS-2, HA-2, et).


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Figure ED-PV-6. External Pressure Thickness Calculations 5) Calculated results and Iterations.

a. If the resulting calculated Pa value is greater than or equal to the design Pa, the results will show as satisfactory and the calculated Pa cell will display a green background.

b. If the resulting calculated Pa value is less than the design Pa value, the background color will turn red signifying that the results were not satisfactory. At this point the user must start an iteration process where the “t” value now must be increased in increments and steps 2 thru 4 are repeated until the resulting calculated Pa is at or above the design Pa value.

Repeat steps 2 through 5 for the External Pressure calculations based

on the given t value (tnom – Ca). Prior to exiting or printing, scroll back to the top and click the [Refresh]

button to ensure all calculations were performed.


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To the right of the minimum thickness calculations is an additional minimum required thickness (tmin) calculation based on an E value of 1 that should be used when doing nozzle tmin, reinforcement (tr value) and hoop stress calculations for localized corroded areas more than an inch away from any weld seam.



To print, ensure to click the [Refresh] then click the print preview icon (page w/ magnifying glass) in upper right hand corner then select print from the preview page. NOTE: Click on save icon in upper right hand corner before selecting print preview.


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Spherical Shell Calculations

Figure ED-PV-7. Spherical Shell Calculations

To access the Spherical Shell Calculations page from the front page, choose [Engineering Data] then click [PV Calculations] then choose [Spherical Shell]. This page can be accessed from the Report Builder as well. Reference PV Calculation General Instructions at the start of the PV Calculations Section of this instruction manual to begin performing these calculations.

The Static Height (SH) value is normally the vessel liquid operating level height (in feet) from the bottom most elevation of the sphere (or bottom of corroded area of interest where localized corrosion is being evaluated), if the vessel has a liquid operating level. If the vessel is used in gaseous service the SH value is “0”.


For Material Selection, Stress (S) Values, and Joint Efficiency (E)

Reference PV Calculation General Instructions at the start of the PV Calculation Section of this instruction manual for instructions.


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External Minimum thickness:

Vessels that are rated for full vacuum (denoted on the U1 for as FV in the MAWP line) should have a value of 15 entered into the “Vac PSI” (normal atmospheric pressure is 29.9 wc (inches of Water Column) which equals to 14.7 psi and therefore a full vacuum would produce 14.7psi (rounded to 15 psi) of external pressure on the vessel.

The “Design Pa” considers the sum of Design Internal Vacuum (ext. psi) + Jacket MAWP (psi).

Calculating minimum thickness requirements for external pressures for spherical type components i.a.w. ASME Section VIII, Division 1, requires making several iterations using estimated thicknesses and solving for Pa (pressure) referencing external pressure charts (X-Charts). as follows:

1) Ro = outside radius of the shell under consideration, in inches. 2) Determine starting value t where t = the minimum thickness (tmin) for

the vessel part under consideration required to resist external pressures. This t value should start with the tmin required for internal pressures as this value cannot be less that that required for internal pressure.

3) Applicable X-Chart - The Applicable X-Chart will populate the X-

Chart Cell based on the material chosen. The user has the option of viewing the material data form to verify information associated with that material. Click on [Material] button below the calculation (if error message pop ups click [refresh] button and retry). This will bring up the related material spec from which the user must note the applicable X-Chart (to the right of the spec. form). The referenced X-Chart can be overwritten by inputting the new Figure ID in the user defined cell below the default cell.

4) For determining A and B (E) Values, Reference PV Calculation General Instructions at the start of the PV Calculations Section of this instruction manual for instructions on using the X-Charts (Fig G, CS-2, HA-2, et). 5) Calculated results and Iterations.




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Prior to exiting or printing, scroll back to the top and click the [Refresh]

button to ensure all calculations were performed. To the right of the minimum thickness calculations is an additional

minimum required thickness (tmin) calculation if an E value less than one is used in the main tmin calculation that should be used when doing nozzle tmin, reinforcement (tr value) and hoop stress calculations for localized corroded areas more than an inch away from any weld seam.


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Conical Shell Calculations

To access the Conical Shell Calculations page from the front page, choose [Engineering Data] then click [PV Calculations] then choose [Conical Shell]. This page can be accessed from the Report Builder as well. Reference PV Calculation General Instructions at the start of the PV Calculations Section of this instruction manual to begin performing these calculations.

Please reference the Cylindrical Shells Calculation for guidance on use as the details of use are the same. Braced Surface Calculations

To access the Braced Surfaced Calculations page from the front page, choose [Engineering Data] then click [PV Calculations] then choose [Braced Surfaces]. This page can be accessed from the Report Builder as well. Reference PV Calculation General Instructions at the start of the PV Calculations Section of this instruction manual to begin performing these calculations.

Dimpled Jacket Calculations

To access the Dimpled Jacket Calculations page from the front page, choose [Engineering Data] then click [PV Calculations] then choose [Dimpled Jacket]. This page can be accessed from the Report Builder as well. Reference PV Calculation General Instructions at the start of the PV Calculations Section of this instruction manual to begin performing these calculations.


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Half Pipe Jacket Calculations

Figure ED-PV-.8 Calculations for Half Pipe Jacket

To access the Half Pipe Jacket Calculations page from the front page, choose [Engineering Data] then click [PV Calculations] then choose [Half Pipe Jacket]. This page can be accessed from the Report Builder as well. Reference PV Calculation General Instructions at the start of the PV Calculations Section of this instruction manual to begin performing these calculations.

Size and schedule pull down selections are based on NPS pipe but may take user defined values instead. Fill yellow user defined cell to overwrite tnom if size is not taken from selection menu.

The Attaching Component Variables section requires input from the component (Cylindrical Shell or Formed Head in most cases) that the Half Pipe Jacket is attached to. These components must be calculated separately from the Jacket calculation and resulting values inputted into the associated input cell (Dv, tv, Pv, et.). There are buttons in this section that will open the calculations for those components. Note that if the attaching component was previously calculated, it will open it if the "Project No." is the same otherwise it will open a blank report to be filled in accordingly.


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The K factor must be obtained from Fig. EE-1, EE-2, or EE-3 of ASME Sect. VIII, D1 Non-Mandatory App. EE.

For Material Selection, Stress (S) Values, Joint Efficiency (E) and Printing - Reference PV Calculation General Instructions at the start of the PV Calculation Section of this instruction manual for instructions.


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Formed Head Calculations

Figure ED-PV-9. Formed Head Calculations

To access the Formed Head Calculations page from the front page, choose [Engineering Data] then click [PV Calculations] then choose [Formed Heads]. This page can be accessed from the Report Builder as well. Reference PV Calculation General Instructions at the start of the PV Calculations Section of this instruction manual to begin performing these calculations.

The Static Height (SH) value is normally the tank liquid operating level height (in feet) from the bottom most elevation of the head of interest of a vertical vessel (or bottom of corroded area of interest where localized corrosion is being evaluated), if the vessel has a liquid operating level. If the vessel is used in gaseous service the SH value is “0”. Horizontal vessels “SH” would be the height (in feet) from the bottom most elevation up to the operating liquid level along an axis in the diametric center of the cylinder cross section. Static head is taken as water (SHw) for a Specific Gravity (SG) of 1.0 in the calculation. For product with a SG above 1.0 (SGp), Multiply the normal SH by the Product SG (SHw x SGp = SH) to account for the difference in the calculation.


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Figure ED-PV-10. Liquid Level for Static Head (SH) Determination


Select the “Type Head” that will be the basis for the input data and calculations.


NOTE: For seamless heads, E = 1.0 when vessel is stamped RT-1 or RT 2. E = 0.85 when the radiographic exam does not meet the requirements for RT 1 or 2 stamping, or when the Category A or B welds connecting seamless vessel components or heads are Type No. 3, 4, 5, or 6 of table UW-12.

K1 Variable for Ellipsoidal Non-Typical heads –Once the h value is

entered into the calculation for non-typical ellipsoidal heads click on the [Table UG-37] button just below the cell. Note the D/2h value in the top left corner. Find that value on the chart and note the corresponding K1 value. If the D/2h value falls between listed values, enter the next higher value into the interpolation table in the lower half of the form and note the resulting K1 value in the box to the right


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of the interpolation table. Close out the popup table 31 and enter the resulting K1 value in the K1 cell.

External Minimum thickness: Skip this section if not applicable. Vessels that are rated for full vacuum (denoted on the U1 for as FV in the

MAWP line) should have a value of 15 entered into the “Vac PSI” (normal atmospheric pressure is 29.9 wc (inches of Water Column) which equals to 14.7 psi and therefore a full vacuum would produce 14.7psi (rounded to 15 psi) of external pressure on the vessel.

The “Design Pa” considers the sum of Design Internal Vacuum (ext. psi) + Jacket MAWP (psi).

Calculating minimum thickness requirements for external pressures for formed head type components i.a.w. ASME Section VIII, Division 1, requires making several iterations using estimated thicknesses and solving for Pa (pressure) referencing external pressure charts (X-Charts). as follows:

1) Determine values L & R - L = the inside spherical or crown radius of the head under consideration, in inches and r = inside knuckle radius, in inches.. These values are automatically determined by the program except for the Torispherical values of which can be obtained from the U1 data sheet.

2) Ro Variable for Ellipsoidal Heads –If the Ro value in the yellow cell of the ellipsoidal head section shows “error” and the yellow message box reads “Reference Table UG-33.1” then note the Do/2Ho value in the green cell and click on the [Table-33.1] button. Find and note the next higher Do/2Ho value. Close out the table and enter that number in the white cell just under the [Table 33.1] button. The error messages should go away and the correct Ro number should appear.

3) Determine starting value t where t = the minimum thickness (tmin) for the vessel part under consideration required to resist external pressures. This t value should start with the tmin required for internal pressures as this value cannot be less that that required for internal pressure. Upon entering a value into the t cell for external pressure the Ro and A value should automatically fill in.

4) Applicable X-Chart - The Applicable X-Chart will populate the X-Chart Cell based on the material chosen. The user has the option of viewing the material data form to verify information associated with that material. Click on [Material] button below the calculation (if error message pop ups click [refresh] button and retry). This will bring up the related material spec from which the user must note the applicable X-Chart (to the right of the spec. form). The referenced X-Chart can be overwritten by inputting new Chart ID in the user defined cell below the default cell.


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Figure ED-PV-11. External Thickness Calculations for Heads 5) For determining B (E) Values, Reference PV Calculation General Instructions at the start of the PV Calculations Section of this instruction manual for instructions on using the X-Charts (Fig G, CS-2, HA-2, et).

6) Calculated results and Iterations.




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Prior to exiting or printing, scroll back to the top and click the [Refresh] button to ensure all calculations were performed.

To the right of the minimum thickness calculations is an additional minimum required thickness (tmin) calculation if an E value less than one is used in the main tmin calculation that should be used when doing nozzle tmin, reinforcement (tr value) and hoop stress calculations for localized corroded areas more than an inch away from any weld seam.


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Head Data

To access the Head Data page from the front page, choose [Engineering Data] then click [PV Calculations] then choose [Head Data]. This page can be accessed from the Report Builder as well.

Choose head design of interest. Select the nominal head diameter. The table gives nominal volume and weight per thickness.

Toriconical Head Calculations

To access the Toriconical Head Calculations page from the front page, choose [Engineering Data] then click [PV Calculations] then choose [Toriconical Head]. This page can be accessed from the Report Builder as well. Reference PV Calculation General Instructions at the start of the PV Calculations Section of this instruction manual to begin performing these calculations.

Please reference the Cylindrical Shells Calculation for guidance as the details of use are the same.


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Flat Heads Calculations

Figure ED-PV-12. Calculations for Flat Heads To access the Flat Heads Calculations page from the front page, choose

[Engineering Data] then click [PV Calculations] then choose [Flat Heads]. This page can be accessed from the Report Builder as well. Reference PV Calculation General Instructions at the start of the PV Calculations Section of this instruction manual to begin performing these calculations.

Fill yellow cells only for welded heads (input d value in G cell) and Fill all cells for bolted heads, enter a value in all cells, "0" if a value is not applicable (such as Ca).



There are assorted buttons for access data as needed to determine

required values for variables.


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The [Flange Data] button may be referenced to determine specification values for B16.5 type flanges according to class and size. (click [Flange Data] and [Weld Neck] and select size for cover plate specs that include variables A, B, C, N and t).

The [Bolting Values] button may be referenced to determine specification values for Bolting. (click [Bolt Values] and select size or Material for bolting specs that include variables ab, Sba and Sbo.

The [Gasket Data] button may be referenced to determine specification values for gaskets. (click [Gasket Data] and select Gasket type and thickness for specs that include variables Y, M, G, and b. NOTE: Also see Gasket Data under Design Data for more details regarding using the gasket data form.

The [Attch. Factor] button may be referenced to determine a coefficient of attachment value. (click [Attch. Factor] and choose from common head configurations. (Reference ASME Section VIII, Div. 1, fig UG-34 for additional design configurations) for 0.specs that include variable c.


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Flat Non Round Covers Calculations

Figure ED-PV-13. Calculations for Flat Non Round Cover

To access the Flat Non Round Cover Calculations page from the front

page, choose [Engineering Data] then click [PV Calculations] then choose [Flat Non Round Cover]. This page can be accessed from the Report Builder as well. Reference PV Calculation General Instructions at the start of the PV Calculations Section of this instruction manual to begin performing these calculations.

Please reference the Flat Head Calculation for guidance as the details of use are the same.


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Nozzle Calculations

Figure ED-PV-14. Calculations for Nozzles

To access the Nozzle Calculations page from the front page, choose [Engineering Data] then click [PV Calculations] then choose [Nozzles]. This page can be accessed from the Report Builder as well. Reference PV Calculation General Instructions at the start of the PV Calculations Section of this instruction manual to begin performing these calculations.

Please reference the Cylindrical Shells Calculation for guidance as the details of use are the same.


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Flange Calculations

Figure ED-PV-15. Calculations for Flanges per ASME Sect. VIII D1, App. 2

To access the Flange Calculations page from the front page, choose [Engineering Data] then click [PV Calculations] then choose [App 2 Flanges]. This page can be accessed from the Report Builder as well. Reference PV Calculation General Instructions at the start of the PV Calculations Section of this instruction manual to begin performing these calculations.



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Standard Flanges

To access the Standard Flanges page from the front page, choose [Engineering Data] then click [PV Calculations] then choose [Stnd Flanges]. This page can be accessed from the Report Builder as well.

Please reference the [Pipe Standards] Section in the [Engineering Data] pick list for guidance as the details of use are the same. Nozzle Reinforcement (Repad) Calculations

Figure ED-PV-16. Repad Calculations

To access the Repad Calculations page from the front page, choose [Engineering Data] then click [PV Calculations] then choose [Repad's]. This page can be accessed from the Report Builder as well. Reference PV Calculation General Instructions at the start of the PV Calculations Section of this instruction manual to begin performing these calculations.


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The value of (F) – F = value of 1 except for integrally reinforced openings. F is a correction factor for integrally reinforced openings in which case the user must refer to ASME Sec VIII, Div UG-37 and Fig UG-37 to determine that value.

For the Noz Confg. Cell, the user must select condition 1, 2 or 3 where: 1 = the nozzle butting up to the shell and the hole cut opening is flush with the Nozzle ID, 2 = the nozzle fitting into the shell hole cut opening for the nozzle end to be flush with the Shell ID, 3 = the nozzle fitting through the shell hole cut opening for the nozzle end to be extended past the Shell ID with an additional ID fillet weld. Enter in values for all cells, enter “0” if not applicable.

If the resulting value for the initial calculation is satisfactory (without the reinforcing element calculations) then skip the repad addition and leave cells blank otherwise, enter in values for all cells, enter “0” if not applicable.

There are assorted buttons for accessing data as needed to determine required values for variables.


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Bolting Data

Figure ED-PV-17. Bolting Data

To access the Bolting Data page from the front page, choose [Engineering Data] then click [PV Calculations] then choose [Bolting]. This page can be accessed from the Report Builder as well.

The Bolting Values may be referenced to determine specification values for Bolting. Select Size or Material for bolting specs that include

Note “Size Limits” for use of the stress values.


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Tube Calculations (ASME Sect VIII, UG-31)

Figure ED-PV-18. Tube Calculations

To access the Tube Calculations page from the front page, choose [Engineering Data] then click [PV Calculations] then choose [Tubes]. This page can be accessed from the Report Builder as well. Reference PV Calculation General Instructions at the start of the PV Calculations Section of this instruction manual to begin performing these calculations.




External Minimum thickness: Vessels that are rated for full vacuum (denoted on the U1 for as FV in the

MAWP line) should have a value of 15 entered into the “Vac PSI” (normal


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atmospheric pressure is 29.9 wc (inches of Water Column) which equals to 14.7 psi and therefore a full vacuum would produce 14.7psi (rounded to 15 psi) of external pressure on the vessel.

The “Design Pa” is a user input based on the MAWP (psi) of the shell side or the differential pressure if applicable.

Calculating minimum thickness requirements for external pressures for cylindrical type components i.a.w. ASME Section VIII, Division 1, requires making several iterations using estimated thicknesses and solving for Pa (pressure) referencing external pressure charts (X-Charts). as follows:

1) Determine value L where L = the most critical length (the longest unsupported span) between lines of support along the longitudinal axis of a cylindrical component (i.e. Shell, Nozzle, Boot, et.). Lines of support include any point along in the girth) to resist collapsing such Compression rings, Flanges, Jacket tie-ins and includes 1/3 of the vessel heads measure from the head tangent as illustrated below in Figure PV 13

2) Determine starting value t where t = the minimum thickness (tmin) for the vessel part under consideration required to resist external pressures. This t value should start with a tmin equal to or greater than the tmin required for internal pressures as this value cannot be less that that required for internal pressure.

3) Applicable X-Chart - The Applicable X-Chart will populate the X-Chart Cell based on the material chosen. The user has the option of viewing the material data form to verify information associated with that material. Click on [Material] button below the calculation (if error message pop ups click [refresh] button and retry). This will bring up the related material spec from which the user must note the applicable X-Chart (to the right of the spec. form). The referenced X-Chart can be overwritten by inputting new Figure ID in the user defined cell below the default cell. 4) For determining A and B (E) Values, Reference PV Calculation General Instructions at the start of the PV Calculations Section of this instruction manual for instructions on using the X-Charts (Fig G, CS-2, HA-2, et).





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Repeat steps 2 through 6 for the External Pressure calculations based on the given t value (tnom – Ca).

Prior to exiting or printing, scroll back to the top and click the [Refresh] button to ensure all calculations were performed.


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Tube Sheet Calculations

Figure ED-PV-19. Tube Sheet To access the Tube Sheet Calculations page from the front page,

choose [Engineering Data] then click [PV Calculations] then choose [Tube Sheet]. This page can be accessed from the Report Builder as well. Reference PV Calculation General Instructions at the start of the PV Calculations Section of this instruction manual to begin performing these calculations.


Fill orange cells first then check text in blue below to see if shear needs to be calculated. If shear not controlling, blue cells will not be required to be filled, if shear is controlling blue cells are required to be filled.

The [Gasket Data] button may be referenced to determine specification values for gaskets. (click [Gasket Data] and select Gasket type and thickness for specs that include variables Y, M, G, and b. NOTE: Also see Gasket Data under Design Data for more details regarding using the gasket data form.


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Heat Exchanger Floating Cover Calculations

Figure ED-PV-20. Calculations for Floating Cover

To access the Floating Cover Calculations page from the front page, choose [Engineering Data] then click [PV Calculations] then choose [Floating Cover]. This page can be accessed from the Report Builder as well. Reference PV Calculation General Instructions at the start of the PV Calculations Section of this instruction manual to begin performing these calculations.


The opening page is for tube side (TS) evaluation. Once the data input is complete for the TS then click the [Shellside Calculations] button at the top right to enter the remaining data need to evaluate the SS of the floating head cover. Each side must be printed separately from the associated form report.

The “Design Pa” considers the differential pressures of the TS vs. SS, psi).



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1) Determine value L = the inside spherical or crown radius of the head under consideration, in inches.. This value may be obtained from the U1 data sheet.

2) Determine starting value t where t = the minimum thickness (tmin) for the vessel part under consideration required to resist external pressures. This t value should start with the tmin required for internal pressures as this value cannot be less that that required for internal pressure. Upon entering a value into the t cell for external pressure the Ro and A value should automatically fill in.

3) Applicable X-Chart - Click the [Material] button to the right of the form near the external evaluation at the bottom of the form to determine the appropriate X-Chart. This will bring up the related material spec from which the user must note the applicable X-Chart (to the right of the spec. form).

4) For determining B (E) Values, Reference PV Calculation General Instructions at the start of the PV Calculations Section of this instruction manual for instructions on using the X-Charts (Fig G, CS-2, HA-2, et).

5) Calculated results and Iterations. c. If the resulting calculated Pa value is greater than or

equal to the design Pa, the results will show as satisfactory and the calculated Pa cell will display a green background.

d. If the resulting calculated Pa value is less than the design Pa value, the background color will turn red signifying that the results were not satisfactory. At this point the user must start an iteration process where the “t” value now must be increased in increments and steps 2 thru 5 are repeated until the resulting calculated Pa is at or above the design Pa value.

Horizontal Tanks: Reference Patches under the Engineering Design Data / AST Calculations for instructions.


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Tower Loads:

Figure ED-PV-21. Calculations for Tower loads

To access the Tower Load Calculations page from the front page, choose [Engineering Data] then click [PV Calculations] then choose [Tower Loads]. This page can be accessed from the Report Builder as well. Reference PV Calculation General Instructions at the start of the PV Calculations Section of this instruction manual to begin performing these calculations.

External pressure thickness must be predetermined using the Cylindrical Shell calculations.

A “Tower Piping Worksheet” and “Vessel Weight Worksheet” are available for extraneous calculations that will automatically be factored in once completed and all total weight cells updated in the work forms. The Worksheets will print out with the report if printed via the green report print button..

Enter 0 in cells that are not applicable as all cells must have a value to calculate. .


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Patches: Reference Patches under the Engineering Design Data / AST Calculations for instructions. Expansion Joint MI Evaluation

Figure ED-PV-22. Expansion Joint Evaluation

To access the Expansion Joint Evaluation page from the front page, choose [Engineering Data] then click [PV Calculations] then choose [Expansion Joint]. This page can be accessed from the Report Builder as well. Reference PV Calculation General Instructions at the start of the PV Calculations Section of this instruction manual to begin performing these calculations.

Reference the example report if unsure about the required data.


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MDMT Eval: Reference MDMT Eval under the Engineering Design Data for instructions. API-510 Remaining Life Calculations

Figure ED-PV-23. Component Remaining Life Calculations

To access the API-510 Remaining Life Calculations page from the front page, choose [Engineering Data] then click [PV Calculations] then choose [API-510 Remaining Life]. This page can be accessed from the Report Builder as well. Reference PV Calculation General Instructions at the start of the PV Calculations Section of this instruction manual to begin performing these calculations. Engineering Calcs: Reference Engineering Calcs under the [Engineering Design Data] / [AST Calculations] for instructions.


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Rerate Cove Page

Figure ED-PV-24. Rerate Cover Page

To access the Rerate Cover Page from the front page, choose [Engineering Data] then click [PV Calculations] then choose [Rerate Cover Page]. This page can be accessed from the Report Builder as well. Reference PV Calculation General Instructions at the start of the PV Calculations Section of this instruction manual to begin performing these calculations.

Reference the example report for suggest formatting and required data.


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Pipe Calculations General Instructions

Begin performing Calculations by clicking the [+] icon at the top right hand corner and entering data in cells as called for.

Alternately, in some forms the user has the option of selecting an

existing file and click the duplicate icon at the top right hand corner and update the data as required to reflect the new record.

User defined cells (yellow cells adjacent to or below related cell) are provided to allow the user the option to overwrite certain variables when necessary.

Variable definitions are given in table at right and can be accessed via the pull down menu. Click in the definition box and use vertical scroll to read all text.

Anytime a pull down selection is used and opening, click the [Refresh] button to update form information that is being pulled from external static tables such as the material selection.

Material Selection - The material selection accesses a material list based ASME B31.3 stress values but other material may be entered.

Stress (S) Values - Clicking on the [S] button will access the programs material stress sub tables which base it stress values on ASME B31.



To print, click the print preview icon (page w/ magnifying glass) in upper right hand corner then select print from the preview page. DO NOT print form the data input form! NOTE: Click on save icon in upper right hand corner before selecting print preview.


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Pipe Pressure Calculations (ASME B31.3)

Figure ED-PPG-1. Straight Pipe Pressure Calculations

To access the pipe Pressure Calculations page from the front page, choose [Engineering Data] then click [Pipe Calculations] then choose [Pressure Calculations]. This page can be accessed from the Report Builder as well.

Reference Piping General Instructions at the start of the piping calculations for common functionality. Begin performing Pipe Pressure Calculations by entering required data in white cells as called for.

The Joint Quality Factor (E) can be entered into the yellow user defined cell to override the default value (1)

External Minimum thickness: Piping systems that are rated for full vacuum should be based on a value

of 15 psi (normal atmospheric pressure is 29.9 wc (inches of Water Column) which equals to 14.7 psi and therefore a full vacuum would produce 14.7psi (rounded to 15 psi) of external pressure on the piping system.


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The “Design Pa” is based on calculation from ASME Section VIII, Division 1. Calculating minimum thickness requirements for external pressures for cylindrical type components requires making several iterations using estimated thicknesses and solving for Pa (pressure) referencing external pressure charts (X-Charts). as follows:

1) Determine value L where L = the most critical length (the longest

unsupported span) between lines of support along the longitudinal axis of a cylindrical component (i.e. Shell, Nozzle, Boot, et.). Lines of support include any point along in the girth) to resist collapsing such Compression rings, Flanges, Jacket tie-ins.

2) Determine starting value t where t = the minimum thickness (tmin) for

the vessel part under consideration required to resist external pressures. This t value should start with a tmin equal to or greater than the tmin required for internal pressures as this value cannot be less that that required for internal pressure.

3) Applicable X-Chart - Populate the X-Chart Cell based on the material

chosen. The user has the option of viewing the material data form to verify information associated with that material. Click on [Material] button below the calculation (if error message pop ups click [refresh] button and retry). This will bring up the related material spec from which the user must note the applicable X-Chart (to the right of the spec. form).

4) For determining A and B (E) Values, Reference PV Calculation General Instructions at the start of the PV Calculations Section of this instruction manual for instructions on using the X-Charts (Fig G, CS-2, HA-2, et).




Prior to exiting or printing, scroll back to the top and click the [Refresh]

button to ensure all calculations were performed.


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Pipe Support Calculations

Figure ED-PPG-2 Pipe Support Calculations

To access the pipe Pipe Support Calculations page from the front page, choose [Engineering Data] then click [Pipe Calculations] then choose [Pipe Support]. This page can be accessed from the Report Builder as well.

Reference Piping General Instructions at the start of the piping calculations for common functionality except that variable definitions are found next to each cell. Begin performing Pipe Support Calculations by entering required data in white cells as called for. The L (center Load) variable is the aggregate weight of supported items within the designated Ss (distance between supports in the area of interest) such as the Insulation, Flanges, Valves, and other loads as determined in the previous selections and inputs. Under the "Branch Weight loads" at the bottom of the form enter in any branch(s) between lines of support of the main line in the area of interest. The "Dist. Factor" refers to the points of distribution of the branch of interest in regards to points of support of that branch. For example, if the branch is


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supported at three different points including the point of attachment to the main line it would require a "Dist. Factor" of (3). Include any additional weight within those supports (such as Insulation, Valves, Flanges, et.) under the "Other #" input cell. the D variable refers to distance of piping in linier inches which should include all section within the supported areas. WP is the calculated weight of the pipe and WF the calculated weight of fluid (using SG=1). The aggregate weight of the these branches will automatically be included in the center load of the main line.


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Pipe Branch Reinforcement Calculations

Figure ED-PPG-3 Branch Reinforcement Calculations

To access the pipe Branch Reinforcement Calculations page from the front page, choose [Engineering Data] then click [Pipe Calculations] then choose [Branch Reinforcement]. This page can be accessed from the Report Builder as well.

Reference Piping General Instructions at the start of the piping calculations for common functionality. Begin performing Pipe Branch Reinforcement Calculations by entering required data in white cells as called for.


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Pipe Blind Flange Sizing Calculations

Figure ED-PPG-4 Blind Flange Sizing Calculations

To access the pipe Blind Flange Sizing page from the front page, choose [Engineering Data] then click [Pipe Calculations] then choose [Blind Flanges]. This page can be accessed from the Report Builder as well.

Reference Piping General Instructions at the start of the piping calculations for common functionality Begin performing Pipe Branch Reinforcement Calculations by entering required data in white cells as called for.


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Pipe Flange Calculations

Figure ED-PPG-5. Calculations for Flanges per ASME Sect. VIII D1, App. 2

To access the Flange Calculations page from the front page, choose [Engineering Data] then click [Pipe Calculations] then choose [App 2 Flanges]. This page can be accessed from the Report Builder as well.

Reference Piping General Instructions at the start of the piping calculations for common functionality. Reference [Engineering Data] / [PV Calculations] / [Calc. Flanges] previously discussed for detailed Instructions. Begin performing calculations by entering required data in white cells as called for.


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Pipe Standards: Reference Pipe Standards under the Engineering Design Data for instructions. Bolting: Reference Bolting under the Engineering Design Data for instructions. Patches: Reference Patches under the Engineering Design Data / AST Calculations for instructions. Expansion Joint MI Eval: Reference Expansion Joint MI Eval. under the Engineering Design Data / PV Calculations for instructions. API-570 Remaining Life Calculations

Figure ED-PPG-6 Component Remaining Life Calculations


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To access the pipe Remaining Life Calculations page from the front page, choose [Engineering Data] then click [Pipe Calculations] then choose [API-570 Remaining Life]. This page can be accessed from the Report Builder as well.

Reference Piping General Instructions at the start of the piping calculations for common functionality. Begin performing Pipe Branch Reinforcement Calculations by entering required data in white cells as called for.

Conversions: Reference Engineering Calculations under the Engineering Design Data / AST Calculations for instructions. Engineering Calculations: Reference Engineering Calculations under the Engineering Design Data / AST Calculations for instructions.


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Material Specifications

Figure ED-24. Material Specifications Selection

The Material Specifications can be accessed from the Front Page, Report Builder module and other modules. To access the Material Specifications from the front page choose [Engineering Data] then click on [Material Spec].

The Material Specifications page presents data and information on some of the most commonly used material in the industry and their properties such as Material Stress Values, P and Group Numbers, Chemical Composition, Ultrasonic Velocities, Heating Thresholds, Galvanic Series and the like collected from several sources to be presented all together for the user’s convenience. These sources include material data and stress values based on ASME Section 2 part A thru D, ASME Sections VIII and X as well as other engineering documents common to the petrochemical and power industries.

Other Material specifications are available the bottom of the page via button that include, Definitions, Weld Rods, Modulus of Elasticity, Thermal Coefficient of Expansion, MDMT and PWHT.


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A material not listed may be added and existing material edited via the [Edit/Add Record] button at the top of the page. Clicking the [Edit/Add Record] button will navigate the user to the edit mode where the data can be accessed for editing or new material added.

In the edit mode, begin performing new material record by clicking the [+] icon at the top right hand corner and entering data in cells as called for.

Click the [Chemical Composition] and [S Value] buttons to add the

related data. Alternately, the user can select an existing file and click the

duplicate icon at the top right hand corner and update the data as required to reflect the new record.



Once updates are complete click the save icon at the top right hand corner. Click on the [exit] button to navigate back to Material Specification page.

To print, click the [Print Individual Spec] or [Print Entire Listing] at the top that opens a preview page. Select print form the preview page.


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Weld Rods

Figure ED-25. Weld Rod Selection

Weld Rod data can be accessed from the Front Page, Report Builder module and other modules. To access the Weld Rod data from the front page choose [Engineering Data] then click on file of choice [Material Specifications], then [Weld Rod] button at the bottom of the form. Then choose [SMAW] or [GTAW/GMAW] process.

Use the file selection pull down menu at top to select Base 1 material. Match with Base 2 material to determine preferred weld rod.

On the SMAW Page, select [Alt Weld Rod] for the next preferred weld rod or [Alt Weld Rod 2] for a third choice.

On the GTAW/GMAW Page, the preferred weld rod is listed first in the cell and the next preferred rod after the comma (i.e., E309-16, ERNiCr-3). Click on the [Preferred Gas] button at top of page to view the Preferred Gas(s) following the same suite as the rods with comma separator (i.e., Helium, Argon).

Use the file selection pull down menu from the Weld Rod sub form at bottom to select a weld rod material, stress values and use specifications.


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Modulus of Elasticity (MOE)

Figure ED-26. Modulus of Elasticity (MOE) Selection

MOE data can be accessed from the Front Page, Report Builder module and other modules. To access the MOE data from the front page choose [Engineering Data] then click on file of choice []Material Specifications], then [Mod of Elast] button at the bottom of the form.

Using the pull down menu, select the material type and determine the value at temperature. Values are times 10^-6 (29.5 = 29,500,000 PSI)


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Thermal Coefficient of Expansion

Figure ED-27. Thermal Coefficient of Expansion Selection

TCOE data can be accessed from the Front Page, Report Builder module and other modules. To access the TCOE data from the front page choose [Engineering Data] then click on file of choice [Material Specifications], then [Thermo Coeff.] button at the bottom of the form.

Using the pull down menu, select the material type and determine the value at temperature.


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Product Data

Figure ED-28. Product Data Selection

The Product Data can be accessed from the Front Page, Report Builder module and other modules. To access the Material Specifications from the front page choose [Engineering Data] then click on [Product Data].

The Product Data page presents data and information on some of the most commonly used products in industry, collected from MSDS’s for the user’s convenience. MSDS’s specifications may vary from manufacturer, therefore user must verify data used in calculations.

A product not listed may be added and existing material edited. Enter new product by clicking the [+] icon at the top right hand

corner and entering data in cells as called for.


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Where Latent Heat of Vaporization is unknown, used 50 BTU's per pound for conservative value. (Enter value via the [*] button next to the stored product options pull down.)

Where the M variable is unknown, use 25 g/mol for a conservative value. (Enter value via the [*] button next to the stored product options pull down.)

Use the file selection pull down menu at the top to access a

previous record. A record may be deleted by clicking the red “ال” icon at the top right

hand corner and then confirming the action.


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Pipe Standards

Figure ED-PS-1. Pipe Standards Selection

The Pipe Standards can be accessed from the Front Page, Report Builder module and other modules. To access the Pipe Standards from the front page choose [Engineering Data] then click on [Piping Standards], then choose the subject matter of choice. (Flange Rating, Stress Tables, Pipe Sizes, etc.)


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Class Ratings and Flange Sizes

Figure ED- PS-2. Class Ratings and Flange Sizes Selection

The Class Ratings and Flange Sizes can be accessed from the Front Page, Report Builder module and other modules. To access the Class Ratings and Flange Sizes from the front page choose [Engineering Data] then click on file of choice [Piping Standards], then choose [Class Rating and Flange Sizes] then choose subject matter (i.e. Class Rating, WN Flange, LWN Flange) in the category desired (150lb to 1500lb) or choose Pipe/Noz Size or Gasket Data.


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Class Ratings

Figure ED- PS-3. Class Ratings Selection

The Class Ratings can be accessed from the Front Page, Report Builder module and other modules. To access the Class Ratings from the front page choose [Engineering Data] then click on [Piping Standards], then choose [Class Rating and Flange Sizes] then choose Class Rating in the category desired (150lb to 1500lb).

Scroll through listing to find subject of interest using the arrows at bottom of the form until you find the material in the grouping of interest.

Pressure rating from the relative class is subject to the max design temperature. (i.e., A 150lb rated component made of material - CS in Group 1.1 at <101°F is rated for 285psi and at 250° is rated for 245psi).


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Weld Neck (WN) Flange Data

Figure ED- PS-4. Weld Neck (WN) Flange Data Selection

Weld Neck Flange data can be accessed from the Front Page, Report Builder module and other modules. To access the Weld Neck Flange data from the front page choose [Engineering Data] then click [Piping Standards], then choose [Class Rating and Flange Sizes] then choose Weld Neck Flange in the category desired (150lb to 1500lb).

Use the file selection pull down menu in the upper right hand corner to access size of interest.

Variable definitions are given in table at bottom and can be accessed via the pull down menu. Click in the definition box and use vertical scroll to read all text.


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Long Weld Neck (LWN) Flange Data

Figure ED- PS-5. Long Weld Neck (LWN) Flange Data Selection

Long Weld Neck Flange data can be accessed from the Front Page, Report Builder module and other modules. To access the LWN Flange data from the front page choose [Engineering Data] then click on [Piping Standards], then choose [Class Rating and Flange Sizes] then choose Long Weld Neck Flange in the category desired (150lb to 1500lb).

Use the file selection pull down menu in the upper right hand corner to access size of interest.

Variable definitions are given in table at top of page and can be accessed via the pull down menu. Click in the definition box and use vertical scroll to read all text.


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Carbon Steel (CS) Pipe Size Data

Figure ED- PS-6. Carbon Steel (CS) Pipe Size Data Selection

CS Steel Pipe Size data can be accessed from the Front Page, Report Builder module and other modules. To access the CS Steel Pipe Size data from the front page choose [Engineering Data] then click on [Piping Standards], then choose [CS Steel Pipe Sizes].

Use the file selection pull down menu in the upper left hand corner to access size of interest.

Use the file selection pull down menu in the upper left hand corner of the API Standard Line Pipe subsection to access size of interest.

Stainless Steel (SS) Pipe Size Data

SS Steel Pipe Size data can be accessed from the Front Page, Report Builder module and other modules. To access the SS Steel Pipe Size data from the front page choose [Engineering Data] then click [Piping Standards], then choose [SS Steel Pipe Sizes].



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Aluminum (Alum) Pipe Size Data

Aluminum Steel Pipe Size data can be accessed from the Front Page, Report Builder module and other modules. To access the Aluminum Steel Pipe Size data from the front page choose [Engineering Data] then click on [Piping Standards], then choose [Alum Pipe Sizes].



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Practical Minimum Thickness (tmin) Data

Figure ED- PS-7. Practical Minimum Thickness (tmin) Data Selection

Practical tmin data can be accessed from the Front Page, Report Builder module and other modules. To access the Practical tmin data from the front page choose [Engineering Data] then click on [Piping Standards], then choose [Practical tmin].

Use the file selection pull down menu in the upper left hand corner to access pipe size.

Purpose: Piping being evaluated by inspection departments often run into issues with the default practical (structural) minimum thickness (tmin) as established by some standing instructions and actual thicknesses that are near or below those thicknesses due to schedule of piping (i.e., 8" SS pipe sch 10 is 0.148" nominal where the default structural tmin may be above that at 0.150") or corrosion at a calculable rate causing the inspection intervals and remaining life calculations on lines to be limited to an extremely conservative estimate. Normal protocol at this juncture is to forward the matter to engineering to perform a calculated tmin for a more accurate calculation. As an alternative, use of pre-calculated tmins, yields time & manpower savings by easing engineering workloads and expediting turnaround time on Inspection


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reports and database updates. Use of these pre-calculated minimum thicknesses will be predicated to meeting several prerequisites such as supported length, load limits, pressure and temperature constraints, for example, as designated for "Cal1" and "Cal2" of the module.

Scope: The use of these pre-calculated tmins must fall within strict guidelines as set forth in this instruction. Use of these pre-calculated tmins is limited to carbon steel (grades A106 and A53) and 300 series stainless steel piping utilized in the production processes of client facilities.

General Instructions: The following prerequisites must be concluded before using the pre-calculated tmin values.

1) Use of pre-calculated tmins are restricted to those cases where; a. the default practical (structural) tmin is limiting life or inspection

interval due to database calculations based on the pipe nominal or original base line measurements or

b. the corrosion rates are such that a more accurate calculation is needed to conclude that it is mechanically sound to continue in service and will have the mechanical integrity and remaining life required to continue in use to allow time for a planned replacement (i.e. at next unit TA).

2) Piping design configurations restricted to: a. straight lengths between supports or, b. two directional lengths with one elbow (any degree) between

supports. 3) Two pre-calculated tmins (designated as Cal1 and Cal2) have

been established to provide alternate values under some of the variables in the spreadsheet to satisfy variations in weight loads that are common to piping systems. Variables that do not have the Cal1/Cal2 signifier are applicable to both. NOTE: a Cal2 value may be used for CML's that qualify for Cal1 as it is a more conservative value but not visa-versa.

a. Cal1 - The calculated thickness to be used when the area of interest does not support any addition piping components with weight loads greater than those designated under the Cal1 signifier, (basically allowing for the weight of insulation at the designated thickness).

b. Cal2 - The calculated thickness to be used when the area of interest supports addition piping components commonly associated with a valve set weight load as designated under the Cal2 signifier, (including weight of insulation at designated thickness).

4) Insulation - only calcium silicate (CalSil) or mineral wool (MinWool) are included in the weight loads. Other types can be accepted as long as the weight per unit is verified to be equal to or below that of CalSil or MinWool. Any other type not qualifying as stated must be calculated for weight load.

5) Where lines have two sizes within the area of interest (i.e. 3" reduced to 2") (not including valve components where the reduction is local to the valve) use the more conservative values of the two sizes when determining the qualifying factors.


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6) Variables in the spreadsheet that have (=<) signify that the area of interest must have values that are equal to or less than the designated value in order to qualify.

7) Applicable to internal pressures only, does not include piping under external pressures (i.e., vacuum or jacketed)

Specific Instructions: 1) Choose the applicable spreadsheet (carbon steel or 300 series

stainless steel). 2) Determine if area of interest falls under Cal1 or Cal2 (No

additional piping components use Cal1 or Cal 2, for one valve set use Cal2 only).

3) Determine max loads (Cal2 - no more than one valve set. Reference available engineering hand books or access Engineering Data/Pipe Standards available within this program for weight of piping components).

4) Determine pipe schedule is equal to or less than value designated.

5) Determine design pressure and temperature is equal to or less than values designated.

6) Determine flange ratings in the system are equal to or less than 300#

7) Determine product specific gravity (S.G.) is equal to or less than 1.1

8) Determine support length is equal to or less than value designated under Cal1 or Cal2 as appropriate.

9) Determine type of insulation. (Types other than CalSil or MinWool must be calculated to determine if weight load is acceptable).

10) Determine thickness of insulation is equal to or less than value designated.

11) The pipe hanger size values are given as guidance for conditions were the distance between supports are close to or at the maximum as indicated for that size and option selected (Cal1 or Cal2). If line is supported by pipe hangers, determine that the diameter (dia) and number of pipe (Pp) hangers is equal to (may be less to some degree) the values designated under Pp Hanger Cal1 or Pp Hanger Cal2. If hangers do not meet the criteria for Cal1 or Cal2 as appropriate, the pre-calculated tmin may be used if all other criteria are met, but the hangers should be evaluated by engineering. NOTE: the values not in () as designated under Pp Hanger Cal1 and Cal2 correspond to those values as designated under Hangers No. not in () (Hanger No. is referring to number of hangers required at the corresponding dia.) and like wise those values in () under Pp Hanger Cal1 and Cal2 correspond to those values as designated under Hangers No. in ().


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Pipe Stress Tables

Figure ED- PS-8. Pipe Stress Tables Data Selection

The Pipe Stress Tables can be accessed from the Front Page, Report Builder module and other modules. To access the Pipe Stress Tables from the front page choose [Engineering Data] then click [Piping Standards], then choose [Stress Tables].

Use the file selection pull down menu on left to access material of interest.

A temperature that fall between given values can be interpolated

using the table to the right. A Material not listed may be added and existing material edited.


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Enter new material by clicking the [+] icon at the top right hand corner and entering data in cells as called for.

Alternately, the user can select an existing file and click the duplicate icon at the top right hand corner and update the data as required to reflect the new record.



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Bolting Data

Figure ED- PS-9. Bolting Data Selection

Bolting data can be accessed from the Front Page, Report Builder module and other modules. To access the Bolting data from the front page choose [Engineering Data] then click on [Piping Standards], then choose [Bolting].

Use the file selection pull down menu in the upper left hand corner to access size of bolt for thread specifications and torque lbs values.

Use the file selection pull down menu at the left of the bolt stress subsection to access stress values for the material of interest.


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Gasket Data

Figure ED- PS-10. Gasket Data Selection

The Gasket Data Tables can be accessed from the Front Page, Report Builder module, flange type calculations and other modules. To access the Gasket Data Tables from the front page choose [Engineering Data] then click [Piping Standards], then choose [Gasket Data].

Use the file selection pull down menu at the top to access gasket material/type/size of interest.

Gasket manufacturer specifications should provide M and Y values. Determine T, W and N values (see figure 1 to 6 to right for variable

description) from exiting or proposed gaskets and/or design conditions to enter into the work sheet (use scroll on right to search thru configuration that best fit the existing design of flange of interest) when determining “b’ values for flange calculations.


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A Material not listed may be added and existing material edited via the [Add/Edit] button at top right.

Enter new product by clicking the [+] icon at the top right hand corner and entering data in cells as called for.

A cad drawing (PIC) or small photo clip would be advantageous for the “sketch” cell entry.



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Insulation Data

Figure ED- PS-11. Insulation Data Selection

Insulation data can be accessed from the Front Page, Report Builder module and other modules. To access the Insulation data from the front page choose [Engineering Data] then click on [Piping Standards], then choose [Insulation].

Use the file selection pull down menu at top to access pipe sizes values to determine the associated thickness for the various temperatures.

Click on the [Insulation Description] for use, weight and restriction of various types of insulation.


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Flange Weight

Figure ED- PS-12. Flange Weight Data Selection

Flange Weight data can be accessed from the Front Page, Report Builder module and other modules. To access the Flange Weight data from the front page choose [Engineering Data] then click [Piping Standards], then choose [Flange Weight].

Use the file selection pull down menu at top to access flange sizes to determine the associated weight.


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Valve Weight

Figure ED- PS-13. Valve Weight Data Selection

Valve Weight data can be accessed from the Front Page, Report Builder module and other modules. To access the Valve Weight data from the front page choose [Engineering Data] then click on [Piping Standards], then choose [Valve Weight].

Use the file selection pull down menu at top to access valve sizes to determine the associated weight for the various valves types.


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Pipe Specs

Figure ED-PS-14. Pipe Specifications

Pipe Specifications data can be accessed from the Front Page, Report Builder module and other modules. To access the Process Specs data from the front page choose [Engineering Data] then choose [Pipe Standards] and then [Pipe Specs].

Use the file selection pull down menu at top right to access the specification of interest such as High Temp. Corrosive Refinery Hydrocarbons (F10 C5), Caustic Services (1 to 50%) (M10C B), Steam and Condensate, HP, B31.1 (C60A), et.

These specification are available for adoption as company specifications as accepted by the company engineering dept. It is recommended that use of these specifications be reviewed and cross referenced with the manufacturer specs issued with by the contractor/engineering firm of the piping system of interest and /or existing company specifications. These cross references should be noted in the "X-Reference" block at top of the form (i.e., Litwin Spec / C01, Esso Spec / M312(1PW1A)). These are considered as General Pipe Specs available for common refinery systems that should be reviewed and accepted (signed) by company PE prior to issuance. Alternately these spec are a good tool for QA reference for the Inspector/R. Engineer to check contractor recommendations for New installation, repairs and alteration to existing piping systems.

Add new specifications by clicking the [+] icon at the top right hand corner and entering data in cells as called for.


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Alternately, the user has the option of selecting an existing file and

click the duplicate icon at the top right hand corner and update the data as required to reflect the new specification.

To print, click the print preview icon (page w/ magnifying glass) in upper right hand corner then select print from the preview page.


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Tube Gauge Sizes

Figure ED-PS-15. Tube Gauge Size Selection

Tube Gage Size data can be accessed from the Front Page, Report Builder module and other modules. To access the Tube Gage Size from the front page choose [Engineering Data] then choose [Pipe Standards] and then [Tube Gage Size].

Use the file selection pull down menu at top to access Tube Gage Size gauge values to determine the associated thickness for the various Standards (Note: BWG most common reference in US).


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Minimum Design Metal Temperature (MDMT) Evaluation

Figure ED-29. MDMT Evaluation Data Entry Form

MDMT Evaluation can be accessed from the Front Page, Report Builder module and other modules. To access the MDMT Evaluation from the front page choose [Engineering Data] then click on [MDMT].

Begin performing these calculations by clicking the [+] icon at the top of form and begin entering data in cells as called for.

Reference various reference pages via buttons scattered through

out form (next to applicable variable). Variable definitions are found in text next to variable. Use [Exemptions] button at right to aid in determining if the

component is exempt for the evaluation.


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Use the [Appl Curve] button to determine what curve the material falls under.

Use [Fig UCS-66] in step 2 to determine initial temperature (°F), alternately the tabulated values can be used in lue of the [Fig UCS-66]

Generally, the default ratio in step 3 is adequate for the evaluation, however, an alternate ratio can be determined from the formula S*E*/SE as provided for in Step 3. Additionally, there is the MAWP/MAP ration that can be determined for components not in primary membrane tensile stress (such as flat covers, tube sheet, etc.).

Use [Fig UCS-66.1] to determine final temperature (°F) reduction in step 4 based on the ratio determined in step 3.

Notes may be entered if necessary at the bottom of the form. Notes will appear on the bottom of the page of the report.





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Post Weld Heat Treatment (PWHT)

Figure ED-30. ASME Sect. VIII Div 1, UCS-56 PWHT Requirement Selection

The PWHT page can be accessed from the Front Page, Report Builder module and other modules. To access the PWHT page from the front page choose [Engineering Data] then click [PWHT].

Use the file selection pull down menu in the upper left hand corner to access Material of interest P and Group numbers.



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Definitions

Figure ED-31. Definitions Selection

The Definitions page can be accessed from the Front Page, Report Builder module and other modules. To access the Definitions page from the front page choose [Engineering Data] then click on [Definitions].

Use the file selection pull down menu in the upper left hand corner to access subject of interest.


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Coatings

Figure ED-32. Coatings Data Entry Form

The Coatings page can be accessed from the Front Page, Report Builder module and other modules. To access the Coatings page from the front page choose [Engineering Data] then click on [Coatings].

This page is used for recording coatings used for various conditions and components for future reference.

There is a calculation section for determining surface areas where estimates may be required.

Start new record by clicking the [Add Record] button just below the calculation section at the top of form and begin entering data in cells as called for.

Use the file selection pull down menu in the upper left hand corner to access previous records.


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Sheet Metal Data

Figure ED-33. Sheet Metal Data Selection

Sheet Metal data can be accessed from the Front Page, Report Builder module and other modules. To access the Sheet Metal data from the front page choose [Engineering Data] then click on file of choice [Piping Standards], then choose [Sheet Metal].

Use the file selection pull down menu at top to access sheet metal gauge values to determine the associated thickness for the various Standards.


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Process Specs

Figure ED-34. Process Specifications

Process Specifications data can be accessed from the Front Page, Report Builder module and other modules. To access the Process Specs data from the front page choose [Engineering Data] then choose [Process Specs].

Use the file selection pull down menu at top to access the process of interest such as Carbon Dioxide (CO2), Hydrogen Sulfide (H2S), Polythionic Acid, et.

Charts and calculations are available via access buttons on the left of the form to predict specific corrosion as determined by industry science.

General Eng. Pipe Specs are available for common refinery systems that should be reviewed and acceptance by company PE.

To print, click the print preview icon (page w/ magnifying glass) in upper right hand corner then select print from the preview page.


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API 653 AST Inspection Module API 653 AST Inspection Module Main Page

API 653 AST Module can only be accessed from the Front Page API 653 AST Module is laid out to help you find information quickly

via the diverse functions and text windows. The subject tabs of the text widows and pick buttons help to guide the user to the desired information page through a topical approach.

Figure AST-1. API 653 AST Inspection Module Main Page

The tabulated text windows are designed to facility quick access to information that an Inspector or Reliability Engineer may need in response to questions or inspection finding that requires timely judgment calls. The subject matters are broken down into components (Shell, Fixed Roof, Floor, Shell Nozzles etc.). These component text windows have subsets


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of pages addressing the various disciplines related to assessing the degree of degradation and other discrepancies. The disciplines include Design Criteria, Inspection Guidelines, and Repair Specifications for each of the components.

Procedure for viewing/seeking text window subject matter:

1) Pick on subject tab of interest (Inspection intervals, Shell, Fixed Roof, Floor, etc.).

2) Click in window to activate vertical scroll. 3) Click on arrow button below subject tab (or at bottom of window) to scroll to

discipline of choice (Design Criteria, Inspection Guidelines, Repair Specifications)

4) Use vertical scroll in text window (not vertical page scroll) to peruse the subject matter or reference being sought.

Under each of the tabulated subjects are subset pages with both

references to the codes in regards to that particular area of interest and specification “snap shots” of some of the most commonly accessed code requirements such as in the follow excerpt:

I. DESIGN OF TANK SHELLS A. API STANDARD 650 1. ….. 2. Design Considerations - para 3.2 a. 3.2.4 External Pressures (1 in of water) 3. Shell Design - para 3.6 a. Minimum Design Thickness = 0.188" for tanks <50' dia, 0.25" for tanks <120' dia - para 3.6.1.1 b. Minimum Design Width of shell plates = 72" - para 3.6.1.2 c. Weld Spacing details 3.7.3 c1. Plates >1/2" - 10" min distance from shell to any butt weld shell joint c2. Plates <=1/2" (or thicker plates that were PWHT) - 6" from Vertical joints and 3" from horz. joints (including bottom shell-floor joint).


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Figure AST-2. Tabulated Subject Text Windows

Across the top of the main page of the API-653 module are pick

button linked to the most commonly associated Codes (API-650, API-653, ASME V, etc.) in PDF format to provide quick access to those codes when needed. (No laboring or searching) along with a “Codes” button that will navigate you to additional API, ASME and other associated codes as well.

Buttons along the bottom give you quick access to the work modules (such the Report Builder, Calculations, Engineering Data, Hydro Testing, Repair Specs, etc.).


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Repair Specifications

Figure AST-3. Repair Specifications Data Entry Form

Repair Specifications can be accessed from button at the bottom of the API 653 AST Module. To access the Repair Specifications from the front page choose [API 653 AST] then click on [Repair Specs] button at bottom of page then click on repair spec of interest.

1. General 2. Nozzle Installation, 3. Repad Installation 4. Nozzle Removal 5. Shell Insert, 6. Lap Patch 7. Shell Attachment 8. Support Pads 9. Weld Repairs/Weld Overlay 10. Liner Inst/Repair 11. NDE Forms


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GENERAL TO ALL REPAIR SPECS: Begin project by clicking the [+] icon at the top of form and begin

entering data in cells as called for.

Variable definitions are found in text next to variable. Pick buttons for quick access to commonly accessed specifications

relating to project such as Material Data and Nozzle Data are provided through out the form.

Illustration N1 is for a drawing spec. The button above the Illustration N1 entry cell has a drawing library with several selections related to the subject matter. Users can scroll thru the library using the scroll arrows at the bottom of the drawing window. To select a drawing, right click on the drawing of choice and copy and paste it into the Illustration N1 cell. Alternately, the user can make a new drawing and insert it into the Illustration N1 cell and into the library for future use.

The Weld Data section should reflect weld data variables (W1, W2, W3, et) from the drawing and should be cross referenced to Illustration N2 (Weld Design Figures) specifying the figure(s) and unit values.

Fill procedural specifications in thorough detail for maintenance and inspection directives.

Attach any additional drawing if required to support repair specifications. GENERAL REPAIR SPECS: The General Specification allows the user to specify variables. The

variables should reflect any variables referenced in the drawings (Illustration N1).

The General Repair Spec provides an Illustration N3 entry for additional drawings along with addition text cell next to it.


Use the file selection pull down menu at the top of the page to access a previous record.



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Inspection Forms (Field Forms) Inspection Forms can be accessed from button at the bottom of the

API 653 AST Module. To access the Inspection Forms from the front page choose [API 653 AST] then click on [Inspection Forms] button at bottom of page then click on Inspection form(s) required for Inspection Scope (API Checklist, Component CML Data sheet, AST Settlement Survey, et).

To print, select print from the preview page. AVAILABLE FORMS: Checklists (3):

D. Print checklist as required for type of inspection a. API C-1 In-Service Inspection Checklist, b. API C-2 Out-of-Service Inspection Checklist c. STI Inspection Checklist

Tank Data: 1. Data form for collecting static data about the tank. CML Field Data Collection Sheets (Components and Nozzles): 1. Start numbering the Component CML data form first then

continues from last number in sequence on the Nozzle CML form. 2. Component Description (Comp Disc) refers to Shell 1, Shell 2, 6”

Noz etc.) 3. Location refers to where the CML’s were established (i.e., for

Components - Chime Q1-Q2, Roof X leg 1, Drop 1 Shl1, et; for Nozzles – Noz A, B, C et)

4. All Nozzle X coordinates are measure as straight lengths from seam 1. Seam one is the first seam left of the Manway left of the ladder looking form elevation view.

5. All Nozzle Y coordinates are measure from the floor lip extension.

Shell layout Coordinates Data Sheet: 1. Record Individual shell heights. 2. Seam one is the first seam left of the Manway left of the ladder

looking from elevation view. All X coordinates are measures as straight lengths from this point. (this includes all nozzles, weld seams and appurtenances)

Seal Inspection Field Data Sheet: 1. Criteria for this evaluation is from EPA REGULATIONS 40 CFR

Chapter 1, Part 60. 2. Record seal gaps as ½ the gap length. The entry to determine

square inches is based on normal physical profiles where the gap starts


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from point “A” and gradually widens at an angle to its max width from the shell at point “B” then tapers back at an angle to point “C” on the other side. Theoretically, splitting the gap length at point “B” (in half), inverting, and folding back onto the remaining half would form a rectangle, therefore the square units (inches) can be determine from the width times half the length.

Shell Settlement Survey Field Data Sheet:

Figure AST-4. Shell Settlement Survey Field Data Entry Form

The settlement survey from has a preliminary form that should be filled out with basic information prior to issue of the field inspection sheet. The preliminary form calculates survey points to even numbers to better fit a cosine curve.

The max distance between survey points is to be limited to 31.42 ft for ease of computation (max allowed by code is 32 ft)


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Begin entering data into the Shell Settlement Survey preliminary

calculation by clicking the [+] icon at the top right hand corner and entering data in cells as called for.

Use the file selection pull down menu at the top of the page to access a previous record.



NDE Field Data Sheet: 1. Hydro Test form 2. MT Exam Form 3. PT Exam Form AST Repair Hold Point: 1. AST Floor Hold Points 2. AST Shell Hold Points 3. AST Roof Hold Points Begin building the AST Repair Hold Point document by clicking the

[+] icon at the top of form and begin entering data in cells as called for.

Begin entering inspection hold points in the existing data cells in the

form sub section. To enter another component click the [+] icon or select the Duplicate Icon in the component data sub section (not at top of page).


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Figure AST-5. Hold Point Document Data Entry Form

Each “No” (Number) cell should have a value entered for sequence

of events. User can change numbers around if need be to correct a sequence if desired. The field sheet will print in corrected sequence and will open in sequence next time page is accessed.

Click the [Action Icon] button at top to use a “STOP” or “NOTE” in the action cell as appropriate (or leave blank if at a subject heading). Right click on the Icon of choice and copy and paste into the Action cell.

Use pull down menu to insert pre-formulated hold point event text or write in hold point event, heading or note in the sequence as desired.


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User can add a hold point to pull down via button at bottom of page for future use.

Use pull down menu to insert test required text or write in required test. User can add a test to pull down via button at bottom of page for future use.

References to code requirement for tolerances and NDE inspection are available to the user via the pick buttons at the bottom of the pages.

To print, click the [Preview Document] button at the top then select print from the preview page. NOTE: Click on save icon in upper right hand corner before selecting [Preview Document] button.

Notes may be entered between action items as desired. Pre-formulated notes are available to enter via the selection pull down menu at the bottom of the Shell Hold Points document only. User can add notes to pull down selection via button at bottom of page for future use.


A record may be deleted by clicking the red “ال” icon and confirming (Delete all sub record first than the main record).


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AST Hydrostatic (Hydro) Test Calculations

Figure AST-6. Hydro Test Calculation Data Entry Form

The AST Hydro Test calculations can be accessed from the Front Page, Report Builder module and other modules. To access the AST Hydro Test calculations from the front page choose [API 653 AST] then click on [Hydro Testing] button at bottom of page.

Begin performing AST Hydro Test calculations by clicking the [+] icon at the top right hand corner and entering data in cells as called for.

Variable definitions are given in table at middle right of the data

form and can be accessed via the scroll arrow buttons at the bottom of the sub page. Use the side bar scroll to scroll down to review excerpts from API-653 Standard for guidelines for conditions requiring hydro testing.


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The fill height (TH) value is normally the tank height but may be decreased if the calculated result values are not acceptable for any of the courses. The lowest fill height results next to each course would be the target FH. If all results are > FH, no adjustment is required, if results are < FH, then decrease the fill height by subtracting from the course fill height (staring from the most upper course working down) until you get a satisfactory result. If that is the case, the fill height and governing course should be noted in the note section provided at the bottom.



The material selection accesses a material list from API-650 but other material may be entered. If a material not on the default list is used then the material stress will have to be entered via the yellow cell under “User Defined” next to the default stress (St) cell. Clicking on the [User Defined] button will access the programs material table which bases it stress values on API-650. User must select the material from the pull down which, once chosen, the form will display the stress values to be used for the applicable courses in accordance with API-650. The user will then have to enter the resulting values into the associated cells.

“Course Height” is the measured height of product up the course of interest in feet (i.e. an eight foot course with product up to six and half feet would be 6.5, do not use tick (‘) marks for feet, just enter the number (6.5)) and is used to calculate FH

Click on the [logo] button at the top of form to enter user company logo to appear on the reports (changing the logo is global, all reports through out the program will display the logo)

Users can fill in the form with available information and specifications (Target Fill Height, Hold Time, etc.) prior to Hydro testing to be issued to the responsible party directing the hydro. The responsible party directing the hyrdo is to complete the record with the actual event data (Act. Fill Height, Start Time/Date, End Time/Date, etc.). Once the record is returned to the user, the remaining entry data can be entered and the record reissue for signatures for hard copy file.

Notes may be entered in the comments section if necessary in the lower right hand corner. Notes will appear in the comments section of the report.




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API 653 Inspection Report Builder

Figure AST-7. API 653 Inspection Report Builder Data Entry Form

To access the API 653 Inspection Report Builder from the front page choose [API 653 AST] then click on [Report Builder] button at bottom of page. Choose [New Report] or [Select Existing Report] from the popup screen.

Choosing [New Report] and enter a “Report No.”. Begin report by entering data in cells as called for. Choose Units (US or Metric) in upper right hand corner and enter

all data as called for in those units. (Note: once the units are chosen and data is input in those units, changing the units designation will not convert units as entered and will produce erroneous calculations)

Much of the numerical data entered on the report builder front page will be used in the calculations of sub forms, therefore enter all numerical data as specified without signifiers (i.e., “Nominal Diameter” should be enter as 25 not 25’ or 25ft ect.). The “Original Plate Thickness” in lower right corner must be entered specifically using at least the ones place (enter 0 if below 1”) and to the thousandths place for a professional appearance in the final report (i.e. x.xxx [0.500] not .xx or x.x).

The [Edit Component Data] button is available to edit values or text in the report if a value was entered erroneously and needs to be deleted from the cell or an alternate value is required with less placements.


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The Age/Prev Insp. is a number not a date (i.e., 9, 20, 34, et) which will be used to calculate corrosion rates, therefore the “Original Plate Thickness” must correspond with the “Age/Prev Insp” value.

Entry data cells with [*] buttons next to them allows for additions to be entered for use in pull down menus that are not available. (i.e. Inspector or Service. This allows the user to build the data base with data for future usage.

A link to the PDF Codes/Standards library is available in the upper right corner for quick access to the codes.

A link to the extraneous AST Calculations is available where additional calculations may be needed. Click on [AST Calculations] and then select the calculation of interest. (Reference pg 10 – 57)

The cover text comes in with a default text that needs to be edited to reflect associated information. Alternately, the user may delete the default text and enter other text as desired.

To do a spell check, place the cursing within the text windows and click F7 on the key board.

As the user scrolls down the base page there is a “Pipe/Nozzle Practical tmins” table that will come up. These values default to the program practical tmin values but can be over written by the user. These values will be used throughout the program when evaluation the remaining life of the nozzles.

As the user continues to scrolls down the base page there will be empty user data cells to input additional static data that will appear under the data page 4 along with the given data that automatically populates. The user should experiment with these input data to see how it will appear on the data page.

Once all the front page data cells are populated the user can proceed to the sub forms for Data Evaluations, Write-ups, Recommendations and other report building functions. The user should always progress from left to right when entering data in sub forms as the program cascades information as the report is progressed.

Report Appendix must have an initial entry to run this front page report preview (blank report will come up otherwise). The front page report preview page is limited to the fist four pages of the report.

The [File Table Edit] is available to use when a user has several reports that have repetitive information and desires to duplicate a report to edit data that is different from the originating report. Click on the [File Table Edit], Right click on the left of the report desiring to duplicate. Pick ”Copy”. Right click on the blank field at the bottom of list. Pick “Paste”. This will copy all the front page data and the text field. It does not copy the CML/TML data. Immediately change the report (also user can edit other data in this mode as well). Close this entry form and click on the [Select Existing Report] button and open the new report to continue building the report.


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Click on the [logo] button at the top of form to enter user company logo to appear on the reports (changing the logo is global; all reports through out the program will display the logo)


The material selection accesses a material list from API-650. A record may be deleted by clicking the red “ال” icon at the top

right hand corner and confirming. User should delete all sub form files prior to performing this function on the main data entry page.

To preview and print the front page report section, click the print

preview icon (page w/ magnifying glass) in upper right hand corner then select print from the preview page. NOTE: Click on save icon in upper right hand corner before selecting print preview.

To print the finished Report, click the (green) Report Icon and click print. This will print the front page and the sub forms from left to right up to the “AST Checklists”. Any supplemental documents (such as Extraneous Calculations, NDE Reports, Photographs, Drawings, etc.) must be printed independently. Once the Report is printed is must be assembled inserting the Appended documents in the associated appendix sections.

Import/Export buttons are provided to transfer data from one API Toolbox program to another. There are 5 basic data sets associated with the report that must be transferred.

1. Base Page Report Data 2. Report Appendices 3. Component TML Record 4. Nozzle TML Record 5. Settlement Survey

Import/Export commands transfer data using excel spreadsheets as a transfer medium. When the data is in excel it should not be edited or modified in anyway or it may not transfer the data properly. This feature is for data transfer between one API Toolbox programs to another only and cannot be used to input data from other sources such as data loggers.


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Procedure for transferring data: 1) Create a transfer file folder for temporary file storage in

source PC (i.e, inspector’s field laptop). 2) Export all the following data sets for the report of interest

from the API Toolbox Report Builder to the designated transfer file folder. (do not rename files)

a. Base Page Report Data b. Report Appendices c. Component TML Record d. Nozzle TML Record e. Settlement Survey

3) Save files from the source transfer folder to a transfer

medium (i.e. USB Storage, CD) or attach files to email for delivery to destination PC/ API Toolbox program.

4) In the destination PC (i.e,. the technical writer’s PC), create a transfer file folder for temporary file storage.

5) In the destination API Toolbox program, open a random report in the Report Builder and export all data sets, as instructed in step 2 above, to the transfer file folder. (this is done to enable the import command to target a folder to retrieve the data sets from (do not rename of files)..

6) Delete the exported excel data files from the transfer folder and then copy the source excel data files from the transfer medium or email into the transfer folder. (do not rename files)

7) From the destination PC/ API Toolbox random report, Import the following data sets. (caution: ensure that the files to be imported have a unique report number from any existing report or the reports will be merged and cause printing errors)

a. Base Page Report Data b. Report Appendices c. Component TML Record d. Nozzle TML Record e. Settlement Survey

8) Click the [Open Existing Report] button, find the newly imported report and open.


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Report Config. / Appendix

Figure AST-8. Report Appendix Builder

To access the Report Config. / Appendix page from the front page, choose [API 653 AST] then click on [Report Builder] button at bottom of page. Choose [New Report] or [Select Existing Report] from the popup screen, then Click on the [Report Config. / Appendix] button at the bottom left.

Report Appendix must have an initial entry to configure the report and run the front page and other text report previews (blank report will come up otherwise). Pick the Appendix A data scroll menu, choose Appendix A. This will configure the report

This section is divided up with separate windows for building the report appendix.

The Report Appendix text comes in with a default text that needs to be edited to reflect associated information. Alternately, the user may delete the default text and enter other text as desired.

The pull down menus for each of the data cells are for user options. To add more options click the [App. Subject] or [App Text] as desired.


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Page 164

Report Component Corrosion Monitoring location (CML) Record

Figure AST-9. Component CML Data Entry Form

To access the Report Component CML Data Form from the front page, choose [API 653 AST] then click on [Report Builder] button at bottom of page. Choose [New Report] or [Select Existing Report] from the popup screen, then Click on the [Component TML Record] button on the left.

Begin entering data in cells in the “Component TML Record” data section as called for.

The CML must be entered by the user in sequence (as completed on the field forms previously review) using three digit entries (i.e., 001, 002, 003)

“Component” entries should reflect single description per component (i.e. all data from shell course one should be have “Shell Crs 1” entered in this field).

“Location” entries should describe a location were a set of thickness measurement (tml’s) were taken on that component (i.e., Chime Q1-Q2 where the “Chime” is the bottom 6” of the first shell course and Q1 indicates the first quadrant of the circumference as layout and identified on the CAD drawings).


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Entries into the CML records may be entered by adding one at a

time or once the first one is entered the user may duplicate that one equal to the amount of CML points (not including Nozzle CML Points) or number of like components and then editing CML numbers and data as needed.

Click on the [US CML Data] or [Metric CML Data] button to enter thickness readings in accordance with the unit designation chosen on the base page. Each CML can receive up to 6 tml points (but may be less). The last entry is for the value that may be used to calculate the corrosion rates and remaining life. That entry is normally the lowest reading of that CML (tml set). Note that the CML descriptions appear at the top of the form to identify what CML is being edited. Close this data form when completed to return to the Component CML Sub form.

At this point the user must make a determination as to the actual thickness value to be entered in the “Actual Plate Thickness (t act)” section at the top for each component. Normally, regardless of the location on the component, the lowest of the tact values for that component is the value to be entered into the associated data cell in the “Actual Plate Thickness (t act)” section. If there is a corroded section that has been evaluated for hoop stress, the resulting average thickness may be entered in place of the lowest reading.

Much of the numerical data entered in this sub form will be used in the calculations sub forms, therefore enter all numerical data as specified. The “tml” values must be entered specifically using at least the ones place (enter 0 if below 1”) and to the thousandths place for a professional appearance in the final report (i.e. x.xxx [0.500] not .xx or x.x).

The [Edit Component Data] or [Edit CML] buttons are available to edit values or text in the report if a value was entered erroneously and needs to be deleted from the cell or an alternate value is required with less placements.




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Report Nozzle Corrosion Monitoring location (CML) Record

Figure AST-10. Nozzle CML Data Entry Form

To access the Report Nozzle CML Data Form from the front page, choose [API 653 AST] then click on [Report Builder] button at bottom of page. Choose [New Report] or [Select Existing Report] from the popup screen, then Click on the [Nozzle TML Record] button at the bottom.

Begin entering data in cells in the “AST Nozzle/Pipe TML Record” data section as called for.

The CML must be entered by the user in sequence (as completed on the field forms) using three digit entries (i.e., 013, 014, 015) and defaults to 001 for example.

The Age is a number not a date (i.e., 9, 20, 34, et) which will be used to calculate corrosion rates, and defaults to the tank age entered in the base page but can be entered to be replaced.

“Comp ID” entries should reflect the nozzle description such as 24" MW or 4” Nozzle.

“Size” enter all numerical data as specified without signifiers (i.e., 2, 6, 8 not 2” or 6in etc.).


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“Location” entries should designate an ID that that identifies it on the drawing (i.e., A, B, C or MW1, N1, N2, N3 et). And will default to “A” to give a starting ID but can be entered in to replace.

“t Nominal” entries are normally derived from the original nozzle specs. This value is used for the tprev value for the remaining life calculations. The users may opt to enter a previous thickness measurement instead of the nominal thickness for more accurate corrosion rates.

The [Pipe Specs] button is available to determine the nominal thickness of the Nozzle. (Reference “Pipe Standards” on pg 67 for more details).

Entries into the CML records may be entered by adding one at a

time or after the first one is entered the user may duplicate that one equal to the amount of CML points (not including Component CML Points) or number of like components and then editing CML numbers and data as needed.

Click on the [US CML Data] or [Metric CML Data] button to enter thickness readings in accordance with the unit designation chosen on the base page. Each CML can receive up to 4 tml points (but may be less). The last entry is for the value to be used to calculate the corrosion rates and remaining life. That entry is normally the lowest reading of that CML (tml set). Note that the CML descriptions appear at the top of the form to identify what CML is being edited. Close this data form when completed to return to the Nozzle CML Sub form.

Much of the numerical data entered in this sub form will be used in other calculation sub forms, therefore enter all numerical data as specified. The “tml” values must be entered specifically using at least the ones place (enter 0 if below 1”) and to the thousandths place for a professional appearance in the final report (i.e.US Units - x.xxx [0.500] not .xx or x.x).

The [Edit CML] button is available to edit the CML data if a value was entered erroneously and needs to be deleted from the cell or an alternate value is required with less placements.

Enter data cells with [*] buttons next to them allows for additions to be entered for use in pull down menus that are not available. (i.e. Component ID Service). This allows the user to build the data base with data for future usage.


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Page 169

Report Nozzle Calculations

Figure AST-11. Nozzle Calculations

To access the Report Nozzle Calculations from the front page, choose [API 653 AST] then click on [Report Builder] button at bottom of page. Choose [New Report] or [Select Existing Report] from the popup screen, then Click on the [Nozzle Calculations] button at the bottom.

Nozzle evaluations are presented in this sub form based on previous data entry and practical minimum thicknesses as recommended in API-570 for pipe tmins. The tmin values use in this toolbox program were derived from the Practical tmin module of this program (Reference page 75 for more details).

NOTE: API-570 7.3 RETIREMENT THICKNESS DETERMINATION Recommends establishing a greater thickness than the calculated thickness to allow for undiscovered metal loss due to general and localized corrosion, unanticipated loadings, and resistance to normal loss.

The default tmin values can be over ridden using the “User Defined” (yellow) data cell at top of page. Click on the CML and enter the new tmin value. Repeat for all CML’s tmins that require editing.


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The [Edit CML] button is available to edit the CML data if a value was entered erroneously and needs to be deleted from the cell or an alternate value is required with less placements.

A [NPS per Noz ID] button is available for a quick reference to the pipe size for the size nozzle that is selected. Click on the CML of interest then click the [NPS per Noz ID] button in the top left corner to view OD and pipe schedules/wall thickness for that Nozzle size. Note that the selection pull down does not work in this mode.

A [Nozzle Standards] button is available for a quick reference to all pipe/nozzle data. Click on the [Nozzle Standards] button then select the subject matter of interest. (Reference page 67 for more details)




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Report Shell Calculations

Figure AST-12. Shell Calculations

To access the Report Shell Calculations from the front page, choose [API 653 AST] then click on [Report Builder] button at bottom of page. Choose [New Report] or [Select Existing Report] from the popup screen, then Click on the [Shell Calculations] button at the bottom.

Begin performing Shell Calculations by entering remaining data in cells as called for in accordance with the unit designation chosen on the base page.


The fill height value is normally the tank height may be decreased if the remaining life or tmin value is not acceptable for any of the courses. If that is the case, the fill height and governing course should be noted in the note section provided at the bottom.



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The material selection accesses a material list from API-650 but other material may be entered. If a material not on the default list is used then the material stress will have to be entered via the yellow cell under [Alt S] next to the default stress (S) cell. Clicking on the [Alt S] button will accesses the programs material table which bases it stress values on ASME Section 2 Part D. User must select the material from the pull down which, once chosen, the form will automatically calculate the stress values to be used for the applicable courses in accordance with API-653. The user will then have to enter the resulting values into the associated cells. New material not on the list may be entered into the Materials form via the Engineering Data module from the front page to be available for use in the shell calculations forms and sub forms.


“Crs H” is the measured height of product up the course of interest in feet (i.e. an eight foot course with product up to six and half feet would be 6.5, do not use tick (‘) marks for feet, just enter the number (6.5)) and is used to calculate H (Fill height minus all Crs H values below course of interest)

Age variable is from entry made o the main page and is a single number (i.e. 4, 10, 13, 20 etc.), not a date.

The [Edit Component CML] button is available to edit the CML data if a value was entered erroneously and needs to be deleted from the cell or an alternate value is required.





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Report Roof Calculations

Figure AST-13. Roof Calculations

To access the Report Roof Calculations from the front page, choose [API 653 AST] then click on [Report Builder] button at bottom of page. Choose [New Report] or [Select Existing Report] from the popup screen, then Click on the [Roof Calculations] button at the bottom.

Begin performing Roof Calculations by entering remaining data in cells as called for in accordance with the unit designation chosen on the base page.



Results that are not within API-653 guidelines will flag “Red” and a text message will appear to suggest directives.

The [Edit Comp. CML] button is available to edit the CML data if a value was entered erroneously and needs to be deleted from the cell or an alternate value is required.


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Notes may be entered if necessary at the bottom of the data page. Notes will appear on the bottom of the page of the calculation report.




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Report Floor MRT Calculations

Figure AST-14. Floor MRT Calculations

To access the Report Floor MRT Calculations from the front page, choose [API 653 AST] then click on [Report Builder] button at bottom of page. Choose [New Report] or [Select Existing Report] from the popup screen, then Click on the [MRT Calculations] button at the bottom.

Begin performing Floor MRT Calculations by entering remaining data in cells as called for in accordance with the unit designation chosen on the base page.


The [Edit Comp. CML] button is available to edit the CML data if a value was entered erroneously and needs to be deleted from the cell or an alternate value is required.

Threshold setting for the MFE floor exam should be considered prior to getting started with the exam to determine a basis to start with. The client should be consulted to obtain information on the tank such as what previous inspections of the tank may have yielded. The variables


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may need to be adjusted as the inspection progresses based on predominant findings such as those listed in 1-6 below.

Determining RTbc and RTip thresholds depends on what the existing conditions for top and bottom side yields. The following are some guidelines to consider:

1. Overall, if the bottom is clean with virtually no “relevant” indications, consider, as a minimum, starting with 40mil material loss (i.e. 0.250” plate would = 0.210” threshold and therefore, RTbc would = 0.21”). Anything less than 40mil would be difficult for MFE technology to pick up in a favorable percentile and therefore is not practical to set the threshold any lower. Remember that just because no relevant indications were recorded doesn’t mean there weren’t any indications at all, just none that were above the threshold or “relevant” or in the red.

2. If the bottom side has just a few areas with significant indications and the top side has a numerous amount of indications, determine max allowable topside pitting that would be cost effective for repairs that would match well with the minimum for the bottom after the few areas are repaired (aim for 40mil material loss as in #1 for RTbc)

3. If the bottom side has a numerous areas with significant indications and the top side has very few areas of indications, determine max allowable bottom side pitting that would be cost effective for repairs that would match well with the minimum for the top after the few areas are repaired (aim for 50 to 70mil material loss for top side pitting)

4. If the both sides have numerous areas with significant indications, determine max allowable top and bottom side pitting that would be cost effective for repairs.

5. If it is realized early on in the exam process that the damage is so severe that replacing the floor plates would be best and most cost effective option, address these issues with the client as soon as possible to deter any unnecessary inspections.

6. Always consider how adding coatings or CP systems will affect the results as well, if it is a viable alternative for the client.

7. For all scenarios, consider adjusting the Or (next inspection period) to limit scope of repairs, if it is a viable alternative for the client.

Notes may be entered if necessary at the bottom right of the data page. Notes will appear on the bottom of the calculation report.


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Report Shell Settlement Survey Calculations

Figure AST-15. Settlement Survey Calculations

To access the Report Settlement Survey Calculations from the front page, choose [API 653 AST] then click on [Report Builder] button at bottom of page. Choose [New Report] or [Select Existing Report] from the popup screen, then Click on the [Settlement Survey Calculations] button at the bottom.

Begin performing Settlement Survey Calculations by entering remaining data in cells as called for. NOTE: Input US Unit values directly in the cells provided, Input Metric Unit values via the [Metric Unit Data] button in upper left hand corner.

Using the field data form, enter the values for each point into the form.

Click on the [Calculation] button at the right of the data point cells. This button will calculate the settlement in accordance with the requirements of Appendix B and product a chart with the points plotted relative to a best fit cosine curve.

The optimum cosine curve must have a value of R^2 greater than 0.90 as set forth in the Appendix B criterion. If this check comes up less


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than that required it may be necessary to re-shoot the settlement using more points.

Notes may be entered if necessary at the bottom of the data page. Notes will appear on the bottom of the calculation report.




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Report Write-up and Recommendations

Figure AST-16. Write-up and Recommendations

To access the Write-up and Recommendations page from the front page, choose [API 653 AST] then click on [Report Builder] button at bottom of page. Choose [New Report] or [Select Existing Report] from the popup screen, then Click on the [Report Write-up] button at the bottom.

The [Codes] button is available for quick access to referencing codes.

The [Calculate Next Inspection Dates (API max)] button is available for calculating the next inspection dates based on maximum allowed per code and may be overwritten if corrosion rates dictate a shorter inspection interval.

This section is divided up with separate windows for reporting findings and making recommendations for the various components.


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The write-up and recommendation text comes in with a default text that needs to be edited to reflect associated information. Alternately, the user may delete the default text and enter other text as desired.

To do a spell check, place the curser within any the write-up text windows or the ES text window (the two must be checked separately) and click F7 on the key board.

Cells across the top require determinations for dates for next inspections intervals and governing component. The governing component is normally the component with the least remaining life.

The “Years to Next Insp”. is a number value with no signifiers, not a date (i.e., 2, 4, 5, et) which is normally 5 years.

The UT Results Summary and Recommendations should address calculation results and any issues that component evaluations yielded.

The Executive Summary (ES) text comes in with a default text that needs to be edited to reflect associated information. Alternately, the user may delete the default text and enter other text as desired. Normally the only discrepancies that make it into the Executive Summary are the items with a significant cost value or issues that are causing some limitation to the operating parameters of the Tank. These items should be in the body of the report and can easily be copied and pasted into the ES with some minor editing.

To do a spell check, highlight the ES text with the curser within any the ES text window (must be checked separately from write-up text windows) and click F7 on the key board.

Note that the Executive Summary does not appear in the Report Write-up preview page but is rather found on the main page preview.




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Report AST Checklists

Figure AST-17. Report AST Checklists

To access the Report AST Checklists page from the front page, choose [API 653 AST] then click on [Report Builder] button at bottom of page. Choose [New Report] or [Select Existing Report] from the popup screen, then Click on the [AST Checklists] button at the bottom.

This section is divided up in two separate windows for building the report checklist. To enter a check pick the [Select Checklist] button at the top right. Highlight the checklist of interest (pick at the top left of the widow above the text, left click and move the mouse down while hold the left mouse button until all text is highlighted). Then right click on highlighted text and pick “Copy”. Close out selection list page and click in the window of choice (normally the fist blank window). Right click and select “Paste”. Repeat for second checklist if required.

Scroll through the list and enter an X in the center of the line for the relevant items that were checked during the inspection. (place the curser in center of check line, back space and type X [Caps])



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Page 184

Report NDE MT/PT Records

Figure AST-18. Report MT Test Record

To access the Report MT/PT Test Record from the front page, choose [API 653 AST] then click on [Report Builder] button at bottom of page. Choose [New Report] or [Select Existing Report] from the popup screen, then Click on the [NDE Records] button then choose the [MT or PT Record].

Begin report by clicking the [+] button at the top left and entered

into the cells in accordance with the field data sheet as cells as called for. Where there are multiple records to document the user can fill out

the first and then click the duplicate button at top left and edit text of duplicate record to reflect the new record as needed.


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The first sheet need only be filled out for a one time inspection. The second sheet can be utilized to support ongoing and multiple

inspection such as would be expected during a tank turnaround involving several modification and repairs.

The record should be printed and signed by all authorized parties for hard copy record.




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Report Shell AutoCAD Inspection Drawings

Figure AST-19. AutoCAD Shell Ledger Drawing

User must have the AutoCAD program (1997 or later version) to use this function.

User must obtain the filed data sheet and drawing relative to this project. (Reference pg 96 for more details on field forms)

To access the Report AutoCAD Inspection Drawings from the front page, choose [API 653 AST] then click on [Report Builder] button at bottom of page. Choose [New Report] or [Select Existing Report] from the popup screen, then Click on the [Cad Drawings] button at the bottom right, then click the [Dwgs/shell.dwg] link to the AutoCAD template. Save the file to the a project folder and pint out the Ledger drawing for reference when building the shell drawing.

Once the cad drawing is open and saved to a project folder, complete the following steps referencing the field data sheets and drawings:

1) Edit all title blocks and drawing text in papers space (PS enter on command line) related to specific report info (Company, Date, and other text as needed to conform to user company drawing protocols).

2) In model space (MS enter on command line), On command line:


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a. Command: insert SHL b. Insertion Point: “0,0” c. X scale factor: enter tank circumference in feet but without any unit signifiers (i.e. 35 ft diameter is 35x PI = 110 ft to be entered as “110” d. Y scale factor: enter tank shell course height in feet but without any unit signifiers (i.e. 8 ft width = 8 ft to be entered as “8” e. Rotation Angle: enter default. f. Command: Zoom to limits (if this does not bring the shell into a full view then zoom to a scale to gain a full view) g. Explode SHL Block

Figure AST-20. Basic Shell Block Insert h. Copy and past from the now existing three tier shell drawing to gain the required number of shell course. d. Delete the vert lines (weld seams) above weld seam #1 at point 0,0 in the upper courses that do not align with the first course vert weld seam at point 0,0 in accordance with field data records and draw in those that do align.


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e. Command: Insert SHLCUT f. Insertion Point: snap to top of vertical weld seam #1 g. X scale factor: Enter default h. Y scale factor: Enter default i. Rotation Angle: Enter default. j. Copy and past the SHLCUT to all the remaining vert placements above the weld seam #1. Copy and past those on the left when done to the weld seam at the right (both represent weld seam #1).

Figure AST-21. Shell Course Layout with “Shlcut Insert” Pattern k. offset the #1 first weld seam in accordance with the field data sheet (i.e. 30’; Command: offset 30’-0”- pick #1 weld and left click mouse to right of the seam) repeat until all lines (weld seams ) are drawn in on the first course. Copy and past the fist course weld seams to any other courses that align with that course. Repeat process for all courses.


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Figure AST-22. Shell Course Layout with Vert. Weld Seam

l. Insert nozzles as indicated on the field drawings. Reference Shell ledger drawing for Nozzle nomenclature (i.e., use N6 block for a to scale 6” Nozzle elevation view, use MW24 block for a to scale 24” Manway elevation view)

1. Command: Insert MW24 Insertion Point: if X = 4’ and Y = 30” enter 4’,30 2. X scale factor: Enter default 3. Y scale factor: Enter default 4. Rotation Angle: Enter default. 5. Explode nozzle block and edit text to associated CML 6. Repeat for all nozzles according to field data. (Reference the ledger sheet for nozzle block names. 7. Insert Repad blocks if desired. (NOTE: as an inspection drawing only that which helps to communicate inspection findings need be included in the drawing)

m. Insert ladder as indicated on the field drawings


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1. Command: Insert LDR Insertion Point: if X = 25’ and Y = 1’ enter 25’,12 2. X scale factor: Enter default 3. Y scale factor: Enter default 4. Rotation Angle: Enter default. 5. If ladder runs opposite insert default then use mirror command to flip it to the correct orientation before exploding. 6. Explode LDR block and edit conform to field drawing.

Figure AST-23. Shell Course Layout with Nozzles and Appurtenances m. Insert any other entities that there are a blocks for or draw in any other objects that are required for inspection drawing as indicated on the field drawings (such ATG, GR, Hand Rails, et)

1. Command: Insert ATG Insertion Point: if X = 27’ and Y = 4’ enter 27’,4’ 2. X scale factor: Enter default 3. Y scale factor: Enter default


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4. Rotation Angle: Enter default. 5. Explode ATG block and edit to conform to field drawing.

Figure AST-24. Shell Course Layout with CML’s and Seam Numbering

N. Add in Weld Seam Numbers O. Add in CML Points

3. If tank is a large tank, recommend drawing the shell initially as one drawing and then saving as, as many drawings needed to reduce the sizes to where all entities are recognizable and all text is legible, rule of thumb at least two to four course sheets per drawing. When doing so remember to edit title block to reflect number sequencing of drawings.


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Report Roof/Floor AutoCAD Inspection Drawings

Figure AST-25. AutoCAD Roof/Floor Ledger Drawing


User must obtain the filed data sheet and drawings relative to this project. (Reference pg 96 for more details on field forms)

To access the Report AutoCAD Inspection Drawings from the front page, choose [API 653 AST] then click on [Report Builder] button at bottom of page. Choose [New Report] or [Select Existing Report] from the popup screen, then Click on the [Cad Drawings] button at the bottom right, then click the [Dwgs/roof.dwg] link to the AutoCAD template. Save the file to the a project folder and pint out the Ledger drawing for reference when building the shell drawing.

Once the cad drawing is open and saved to a project folder as Roof or Floor layout Drawing, complete the following steps referencing the field data sheets and drawings: (references herein are for a roof layout drawing but principles apply to both the floor and roof except for different appurtenances such as nozzles, platforms and stairways which would only be specific to roof layout whereas the floor may have roof columns, sumps and other items)


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2) In model space (MS enter on command line), On command line: a. Command: “C” enter b. Center Point: “0,0” c. Diameter (Rad): enter tank diameter (i.e. 70 ft diameter is to be entered as 70’ d. Command: Zoom All, and bring the roof circle into a full

view to a scale with room around to insert platforms and stairways)

Figure AST-26. AutoCAD Roof Layout Drawing

e. From field drawings and data sheets determine horizontal

weld seam offset distance (normally they are nominally 6 ft) from one another and the roof center and draw horz. weld seams:

1. Command: type “L” enter - snap to left quad - snap to right quad. 2. Command: Offset - 3’


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3. Select Object: Pic weld Line - pick just above line and delete original (center) line 4. Command: Offset - 6’ 5. Select Object: Pic weld Line - pick just above. Repeat until all upper weld lines are in place in accordance with field drawing. Trim all lines outside of roof perimeter

\ Figure AST-27. Roof Upper Horizontal Weld Seams

f. From field drawings and data sheets determine vertical

weld seam placement for upper half and drawing. (normally these can be drawn in free style keeping to a generally close representation to the as built layout.).

g. From field drawings and data sheets determine configuration the lower half of drawing. Normally the lower half is layout identical to the upper half only inverted, therefore, the upper half can be mirrored and then mirror again down the middle, remembering to “delete old objects” when prompted. Any differences can be edited and the vertical weld seams between the upper and lower section can be drawn in.


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Figure AST-28. Roof Upper Vertical Weld Seams

Figure AST-29. All Roof Weld Seams


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h. Insert nozzles as indicated on the field drawings. (normally these can be drawn in free style keeping to a general close representation to the as built layout.). Reference Roof Ledger drawing for Nozzle nomenclatures (i.e., use N6 block for a to scale 6” Nozzle elevation view, use MW24 block for a to scale 24” Manway elevation view)

1. Command: Insert MW24 Insertion Point: pick the location as indicated on the field drawings 2. X scale factor: Enter default 3. Y scale factor: Enter default 4. Rotation Angle: Enter default. 5. Explode nozzle block and edit text to associated CML 6. Repeat for all nozzles according to field data. (Reference the ledger sheet for nozzle block names. 7. Insert Repad blocks if desired. (NOTE: as an inspection drawing only that which helps to communicate inspection findings need be included in the drawing)

i. Insert top platform and ladder as indicated on the field drawings

1. Command: Insert PF Insertion Point: top quad. 2. X scale factor: Enter default 3. Y scale factor: Enter default 4. Rotation Angle: Enter default. 5. Use rotate command to adjust position in accordance with the field drawing and move slightly inward to show handrails as on the roof. 6. Explode PF block and rotate text to a readable orientation and scale if need be to a legible size. 7. Zoom into the area of the Platform to insert ladder. 8. Command: Insert LDR Insertion Point: next to shell near the platform 9. X scale factor: Enter default 10. Y scale factor: Enter default 11. Rotation Angle: Enter default. 12. Explode LDR block and move text to side (scale if need be to a legible size) 13. Use rotate command to position Ladder step next to shell aligned with the platform in accordance with the field drawings.


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Figure AST-30. Ladder and Platform Orientation

j. Determine number of steps required (Rule of thumb number of steps = the tank height in feet, (i.e. tank height = 48 ft, no. of steps = 48) k. Determine degree to array as follows 360 x (Height /Circ) = X (360 x (48/220) = 78 (if CCW or -78 if CW)

1. Use array command: select ladder rung (include both entities) 2. R/P: Enter P (polar) 3. Base/Center: type “Center” and pick the circle (roof perimeter) 4. Number of items: enter no. determined in j above (i.e. 48). 6. Angle to fill (+ = ccw, - = cw) (degree): enter no. determined in k above in (+) or (–) array (i.e. -78 for Clock Wise in this example) 7. Rotate Object (Y): enter default. 8. Zoom to previous view and adjust Zoom at this point to fill most the drawing field.

l. Insert or Draw in any other entities as needed. m. Add CML points


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Figure AST-31. Roof Drawing with Ladder Array and CML Points


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Report Inspection Photograph

Figure AST-32. Photograph Selection

Users may want to develop Inspection Photographs in a Word document. A link to the File Cabinet is provided to access a pre-design Word document to aid in this project

To access the Report Inspection Photographs from the front page, choose [API 653 AST] then click on [Report Builder] button at bottom of page. Choose [New Report] or [Select Existing Report] from the popup screen, then Click on the [Cad Drawings] button at the bottom right, then click the [Photos and Other Files] and then on the File 1 link to the Photographs in a Word template files. Save the file to the a project folder.

Once the Inspection Photographs Word document is open and saved to a project folder, complete the following:

1) Edit all title text in the header space to reflect current project. 2) Delete existing Photographs. 3) Select “Insert” from the toolbar at top,

1. Select Picture From File - Using pull down menu, navigate to Project Files and choose the photo of interest.


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4. Edit the size of pic to allow 2 pics in one page with captions 1. Right click on pic 2. Choose Format Picture 3. Click on “Size” tab 4. Edit height to 4” (the width should automatically size to 5

5.32" 5. Click OK

5. Edit Caption below photo to describe photo shot.

Figure AST-33. Inspection Photograph Word Document


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API 510 PV Inspection Module API 510 PV Inspection Module Main Page

API 510 PV Module can only be accessed from the Front Page API 510 PV Module is laid out to help you find information quickly


Figure PV-1. API 510 PV Inspection Module Main Page

The tabulated text windows are designed to facility quick access to information that an Inspector or Reliability Engineer may need in response to questions or inspection findings that require timely judgment calls. The subject matters are broken down into various headings such as Inspection Intervals, MI Degradation, Inspection Evaluation, etc. to facilitate a more user friendly navigation to information and quick answers to questions. These component text windows have subsets of pages addressing the various disciplines related to assessing the degree of degradation and


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other code requirements. The disciplines include inspection guidelines for assessing degradation, repair specifications for each of the components, code requirements for testing in-service and repaired components.

Procedure for viewing/seeking text window subject matter: 1) Pick on subject tab of interest (Inspection intervals,

Repair/Alterations, Pressure Relief, etc.). 2) Click in window to activate vertical scroll. 3) Click on arrow button below subject tab (or at bottom of window)

to scroll to sub text of choice (Defect Repairs, Alterations, et.) 4) Use vertical scroll in text window (not vertical page scroll) to

peruse the subject matter or locate specific reference being sought.



II. Vessel Parts and Deformation: A. Cylindrical parts shall not deviate from specifications given UG-80. Principally 1% of the nominal diameter B. Formed heads shall not deviate from specifications given UG-81. C. Appurtenances such as reinforcement pad, stiffeners and lugs shall conform to the contour of the shell. (UG-82) D. Minimum Thickness, Remaining Life, and MAWP Calculations: 1. Calculations for minimum thicknesses are taken from the original code of construction, predominantly ASME Section VIII, Division 1 and based on the maximum allowable design pressure for the vessel. a. Minimum thicknesses for the individual vessel parts must be determined before remaining life calculations can be performed. b. Review any U-1 data sheets or other related documentation for any given Minimum thicknesses. c. ….


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Figure PV-2. Tabulated Subject Text Windows


buttons linked to the most commonly associated Codes (API-510, ASME-Section VIII, ASME V, etc.) in PDF format to provide quick access to those codes when needed. (No laboring or searching) along with a “Codes” button that will navigate you to additional API, ASME and other associated codes as well.



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Engineering Data (reference section for Engineering Data previously reviewed)

Repair Specifications: (reference API 653 Module / Repair Specifications previously reviewed)

Welding

Access the Welding page via the API 510 PV Module. Click on the [Welding] button on the bottom of the page. The Welding page is laid out to help the user to find information quickly via the tabulated text windows. The subject tabs of the text widows and pick buttons at the bottom of this page help to guide the user to the desired information page through a topical approach.

Figure PV-3. API 510 PV Welding Specifications


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The tabulated text windows are designed to facility quick access to

information that an Inspector or Reliability Engineer may need in response to questions or inspection findings that require timely judgment calls. The subject matters are broken down into various headings such as Visual Inspections, RT Ratings and Joint Efficiencies, Typical Weld Joints, et., to facilitate a more user friendly navigation to information and quick answers to questions. These subject text windows have subsets of pages addressing the various requirements related to the subject matter and other code requirements.

Procedure for viewing/seeking text window subject matter: 1) Pick on subject tab of interest (Visual Inspections, RT Ratings

and Joint Efficiency, Typical Weld Joints, etc.). 2) Click in window to activate vertical scroll. 3) Click on arrow button below subject tab (or at bottom of window)

to scroll to sub text of choice (Weld Joint Categories, Radiographic Examination (UW-11), "RT" Ratings (UW-11), et.)

4) Use vertical scroll in text window (not vertical page scroll) to peruse the subject matter or reference being sought.



2.3 "RT" Ratings (UW-11) 2.3.1 "RT 1" - when all pressure-retaining butt welds (excluding Category B & C butt welds) associated with nozzles and components that do not exceed NPS 10 nor 1-1/8 in. wall thickness have been radiographically examined the full length in the manner prescribed in UW-51. 2.3.2 "RT 2" - when RT of all the vessel components satisfy the requirements of UW-11(a)(5) and when spot radiography requirements of UW-11(a)(5)(b) have been meet. 2.3.3 "RT 3" - when RT of all the vessel components satisfy the spot radiography requirements of UW-11(b).


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Figure PV-4 . Welding Tabulated Subject Text Windows

Across the top of the main page of the Welding module are pick

button linked to the most commonly associated Codes (API-510, ASME-Section VIII, ASME V, etc.) in PDF format to provide quick access to those codes when needed. (No laboring or searching) along with a “Codes” button that will navigate you to additional API, ASME and other associated codes as well.

Buttons along the bottom give you quick access to the work modules (such Engineering Data, Weld Rod Selection, WPS/PQR Review, WPQ Review, etc.).


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Inspection Forms (Field Forms) Inspection Forms can be accessed from button at the bottom of the

API-510 PV Module. To access the Inspection Forms from the front page choose [API-510 PV Insp] then click on [Inspection Forms] button at bottom of page then click on Inspection form(s) required for Inspection Scope (API 510 Checklist, PV CML Record Form, PV Boiler plate Drawing, et).

To print, select print from the preview page. AVAILABLE FORMS: API 510 Checklists:

A. Print checklist as required from the preview page

PV TML Record Form (Components and Nozzles):

Figure PV-5 . PV TML Record Form

1. Start numbering the Component CML data first then continues in

sequence with the Nozzle CML’s. 2. Component Description (Comp ID) refers to Top Head, Vessel

Shell, Bottom, 24” MW, 6” Noz, etc.)


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3. Location refers to where the CML’s were established (i.e., for Components – Crown Radius, Knuckle Radius, Head Skirt, Upper Shell, Mid Shell, Bttm Shell, et; for Nozzles – Noz A, B, C or N1, N2, N3, et)

4. Service refers to use such as “Product” for components, “Manway”, “Product Inlet”, “Agitator”, et. for Nozzles, .

PV Boiler Plate Templates Dwg : 1. Horizontal Tank Template drawing and Data sheet, 2. Vertical template drawings and data sheet, 3. Boiler plate drawing for component ID and CML locations.

Figure PV-6 . PV Boiler Plate Inspection Form


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NDE Inspection forms (reference section for API-653 Module/Inspection Forms previously reviewed)

PV Hydrostatic (Hydro) Test Calculations

Figure PV-7. Hydro Test Calculation Data Entry Form

The Pressure Vessel Hydrostatic Test calculations can be accessed from the API 510 PV Module. To access the PV Hydro Test calculations from the front page choose [API 510 PV Insp.] then click on [Hydro Test] button at bottom of page.

Begin performing PV Hydro Test calculations by clicking the [+] icon at the top right hand corner and entering data in cells as called for.


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Anytime a pull down selection is used, click the [Refresh] button to

update form information that is being pulled from external static tables such as the material selection.

Material Selection - The material selection accesses a material list based ASME Section 2 Part D stress values but other material may be entered. Select the material of interest from the pull down menu (the pull down menu must be used in order to auto populate the stress (S) value). If a material not on the default list is to be used then you can ether enter in the new material in the (Material) cell and the associated material stress value can be entered in under the default stress (S) cell or preferably, you should enter the material and associated specifications into the materials module via the [Engineering Data]/[Material] buttons.

Stress (S) Values - Clicking on the [98 S] or [00 S] button will access the programs material stress sub tables which base it stress values on ASME Sect 2 Part D. The [98 S] button will access the 4x safety factor stress used to design pressure vessels before 1999. The [00 S] will access the 3.5x safety factor stress values used to design pressure vessels after the change in the ASME 1999 addenda. (user should use the stress value used in the design of the vessel as referenced on the Mfg U1 data sheet). User must note the material “S” associated with the design temperatures.

NOTE 1: the “S” value will default to the stress values at temperature of material selected for the year the vessel was built but may be overwritten by a user defined stress value if different from the default “S” Variable. NOTE 2: API-510 allows the use of the most current code values for use in corrosion calculations, therefore, if a vessel tmin or remaining life value results in limited or expired remaining life based on the original “S” values concluded from the “98 S” tables the user may alternately use the “00 S” value at temperature to gain some operating time on the vessel if the vessel meets the criteria of API-510 7.3 and Figure 8-1 for rerating. Note that as the user scrolls down the form, both the Hydrostatic

and pneumatic test pressures and the reduced exam pressure are calculated.

Click on the “test form” Icon at the top of the page to fill out a test record form. Users can fill in the form with available information and specifications (Design Pressure, Design Temp, Hold Time, etc.) prior to Hydro testing to be issued to the responsible party directing the hydro.


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The responsible party directing the hyrdo is to complete the record with the actual event data (Actual Test pressure, Start Time/Date, End Time/Date, etc.). Once the record is returned to the user, the remaining entry data can be entered and the record reissue for signatures for hard copy file.

Notes may be entered in the comments section if necessary at the bottom of the data cells. Notes will appear in the comments section of the report.

Hydro Test Record Form

Figure PV-8. Hydro Test Record Form

To print, click the print preview icon (page w/ magnifying glass) in upper right hand corner of the test form then select print from the preview page. NOTE: Click on save icon in upper right hand corner before selecting print preview. Note that the second page has the steps and target pressures if a pneumatic pressure test is opted.


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Figure PV-9. API 510 Inspection Report Builder Data Entry Form

To access the API 510 Inspection Report Builder from the front page choose [API 510 PV Insp.] then click on [Report Builder] button at bottom of page. Choose [New Report] or [Select Existing Report] from the popup screen.

Choosing [New Report] and enter a “Report No.” and then select [Open Simple PV Report] or [Open Complex PV Report].

NOTE: (1) Simple PV Report would be selected if the PV of interest is

designed for internal pressure only and includes Drums (vertical and Horizontal), Heat Exchangers, Towers, Reactor Vessels with Half Pipe or dimpled Jackets.

(2) Complex PV Report would be selected if the PV of interest is designed for internal and external pressures (considering ext. pressure from jacketed vessels where the jacket is a sleeved component fitted about the main vessel cylinder and/or heads) and includes Jacketed Vessels, Reactor Vessels, Towers or any vessel type which may operate in a vacuum.

The report should be configured at this point. Pick the [Configure/ Report Appendix] bottom at the bottom left. Select the


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Appendix A pull down and select Appendix A…the report will then be configured…close the Appendix page to get back to the API-510 Report Builder base page.

Begin report by entering data in cells as called for. Much of the numerical data entered on the report builder front page

will be used in the calculations of sub forms, therefore enter all numerical data as specified without signifiers (i.e., “Inside Diameter” should be enter as 60 not 60” or 5ft et.). The “Nominal Thickness” must be entered specifically using at least the ones place (enter 0 if below 1”) and to the thousandths place for a professional appearance in the final report (i.e. x.xxx [0.500] not .xx or x.x).

The Age/Prev Insp. is a number not a date (i.e., 9, 20, 34, et) which will be used to calculate corrosion rates, therefore the “Nominal Thickness” value must correspond with the “Age/Prev Insp” value.

Entry data cells with [*] buttons next to them allows for additions to be entered for use in pull down menus that are not available. (i.e. Inspector or Service). This allows the user to build the data base with data for future access and use.

A link to the PDF Codes/Standards library is available in the upper right corner for quick access to the codes that the user may entered in the system.

A link to the supplemental PV Calculations is available where additional calculations may be needed. Click on [Supplementary Calculations] and then select the calculation of interest.

The cover page of the report comes with a standard introductory text that has fill-ins from the base page, therefore after the base page data input is completed, chose the Print Review icon at the top of the page to preview the front page text of the report and identify cells that don’t fit well with the text. Cells with excessive data strings may need to be shortened to gel with the standard text.


The data entry on the base page has some “distinguishing entries” for components that operate under different conditions such as Heat Exchangers and Reactors where two different chambers or environments may exist. The program defaults [Main Vessel Data] and [Chamber 2 Data] but may be changed to users preference. These “distinguishing entries” will also accommodate local areas of corrosion if the user wants to call them out for special consideration (i.e Shell CA in the pick list = Shell Corroded Area). These “distinguished entries” are separated by Header ID’s where the cell has a pull down selection to identify the specified section (i.e Main Vessel Data and Vessel Jacket Data) to the right of the form. Once selected these nomenclatures will identify the two distinguishing sections through out the report (i.e. Shell and Head component calculations) and on the Vessel Data Page.

To determine type of heads, consider the following:


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Figure PV-10. Formed Head configurations Ellipsoidal heads: Ellipsoidal heads do not have a definite crown or knuckle radii. Ellipsoidal heads are of a semi-ellipsoidal form, in which half the minor axis (inside depth of the head minus the skirt) equals 1/4 of the outside diameter of the head skirt. An acceptable approximation of a 2:1 ellipsoidal head is one with a knuckle radius of 0.17D and spherical radius of 0.9D, where D is the inside diameter. Torispherical heads: Typical torispherical heads have a crown radius equal to the diameter of the skirt and knuckle radius at 6% of the crown radius. The head heights equal approximately 1/6 of the head skirt diameter in most cases. Hemispherical heads: Hemispherical heads are half a sphere attached to the shell The crown radius and the head heights are equal to the shell radius or 1/2 of the shell diameter. Once all the front page data cells are populated the user can

proceed to the sub forms for Data Evaluations, Write-ups, Recommendations and other report building functions. The user should always progress from left to right when entering data in sub forms as the program cascades information as the report is progressed.

Report Appendix must have an initial entry to run the base page report preview (blank report will come up otherwise). The front page report preview page is limited to the fist four pages of the report.


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preview icon (page w/ magnifying glass) in upper mid section then select print from the preview page. NOTE: Click on save icon in upper right hand corner before selecting print preview. Note also that the Executive Summary does not conform to the report until updates are made in the “Inspection Results Writeup” Subform.

To print the finished Report, click the (green) Report Icon and click print. This will print the front page and the sub forms from left to right up to the “PV Checklists”. Any supplemental documents (such as Extraneous Calculations, NDE Reports, Photographs, Drawings, etc.) must be printed independently. Once the Report is printed is must be assembled inserting the Appendix documents in the associated appendix sections.

The [File Table Edit] is available to use when a user has several reports that have repetitive information and desires to duplicate a report to edit data that is different from the originating report. Click on the [File Table Edit] button, right click on the left of the report desiring to duplicate, Pick ”Copy”, Right click on the blank field at the bottom of list. Pick “Paste”. This will copy all the front page and subpage data text fields. It does not copy the CML/TML data. Immediately change the report (also user can edit other data in this mode as well). Close this entry form and click on the [Select Existing Report] button and open the new report to continue editing/building the report.



The report automatically places a signature text for the Inspector on the front page and his signature in Paint Brush format (.bmp) may be inserted into the report at the bottom left “signature” cell. Additionally a second signature text and signature can be added if required at the bottom of the page next to the inspector’s signature.

The material selection found throughout the Report Module will accesses a material list based on specifications from ASME Sec.2 Part D.

A record may be deleted by clicking the red “ال” icon at the top right hand corner and confirming. User should delete all sub form files prior to performing this function on the base page (initial API-510 data entry page).


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Import/Export buttons are provided to transfer data from one API Toolbox program to another. There are 4 basic data sets associated with the report that must be transferred.

6. Base Page Report Data 7. Report Appendices 8. CML Record 9. API-510 Checklist


Procedure for transferring data: 1) Both simple and complex pressure vessel reports must be exported and imported via the Complex PV Report Builder. Open the report of interest (Simple PV Report or Complex PV Report) in the Complex Report Builder. 2) Create a transfer file folder for temporary file storage in source PC (i.e, inspector’s field laptop). 3) Export all the following data sets for the report of interest from the API Toolbox Report Builder and sub forms to the designated transfer file folder. (do not rename files) a. Report Builder Base Page b. Report Appendices c. CML Record d. API-510 Checklist 4) Save files from the source transfer folder to a transfer medium (i.e. USB Storage, CD) or attach files to email for delivery to destination PC/ API Toolbox program. 5) In the destination PC (i.e,. the technical writer’s PC), create a transfer file folder for temporary file storage. 6) In the destination API Toolbox program, open a random report in the Report Builder and export all data sets, as instructed in step 2 above, to the transfer file folder. (this is done to enable the import command to target a folder to retrieve the data sets from (do not rename of files).


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7) Delete the exported excel data files from the transfer folder and then copy the source excel data files from the transfer medium or email into the transfer folder. (do not rename files) 8) From the destination PC/ API Toolbox random report, Import the following data sets. (caution: ensure that the files to be imported have a unique report number from any existing report or the reports will be merged and cause printing errors) a. Report Builder Base Page b. Report Appendices c. CML Record d. API-510 Checklist 9) Click the [Select Existing Report] button, find the newly imported report and open 10) Report write-up paragraphs will need to be re-spaced.


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Config. / Report Appendix

Figure PV-11. Report Appendix Builder

To access the Configure / Report Appendix page from the front page, choose [API-510 PV Insp ] then click on [Report Builder] button at bottom of page. Choose [New Report] or [Select Existing Report] from the popup screen, then select [Open Simple PV Report] or [Open Complex PV Report]. Then from the Report Builder base page click on the [Configure / Report Appendix] button at the bottom left.





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Report Component Corrosion Monitoring Location (CML) Record

Figure PV-12. Component CML Data Entry Form

To access the Report Component CML Data Form from the front page, choose [API-510 PV Insp ] then click on [Report Builder] button at bottom of page. Choose [New Report] or Select [Existing Report] from the popup screen, then select [Open Simple PV Report] or [Open Complex PV Report]. From the Report Builder base page click on the [CML Record] button on the left.


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Begin entering data in cells in the “PV CML Record” data section as called for.

The CML must be entered by the user in sequence (as completed on the field forms) using three digit entries (i.e., 001, 002, 003)

“Component Disc” entries should reflect single description per component (i.e. all data from Component ID “Shell 1” as identified on the Report Builder base page and can be reference in the globe data box in the upper right corner, should have “Vessel Shell” entered in this field if that is what the component “Shell 1” is named). A pick list of the most common choices is provided for convenience and may be added to by clicking on the [*] button to the right of the column title.

The “Age” cell will default to the Age as entered on the Base page but can be over written if the component was subsequently replaced and has a different age value.

The “Type” cell refers to the designation of a part as ether a “Component” or “Nozzle” (any part that is not a nozzle is a component and components are limited to those entered in the base page under the Component ID’s for Heads and Shells). It is very important that this value be entered properly as it will be used to distinguish between the two and limit the tml selection to the proper components. It also separates the two “types” into different fields for progressive evaluations. A pick list is provided for convenience.

Under the “C - Location”/ “N - Noz ID” entries, the components should describe a location were a set of thickness measurement (tml’s) were taken on that component such as the crown radius, head skirt, upper shell, et. ) The nozzle entries under this column should correspond to the ID system used in the inspection drawing to match up the relative data (i.e., A, B, C …MW1, N1, N2 et.). A pick list of the most common choices is provided for convenience and may be added to by clicking on the [*] button to the right of the column title.

The “Service” column has a pick list of the most common nozzle uses to pick from but the user may enter in any service applicable. The list may be added to by clicking on the [*] button to the right of the column title.

The “Size” column has a pick list of the most common nozzle sizes and should be used for the N type (Nozzle) entries because those exact nomenclatures will be “key” to extract stress values from extraneous tables in the nozzle calculations. The C type components remain blank as they have no significant use in sub calculations.

The “N-Sch” column has a pick list of the most common pipe schedules and must be determined and used for the N type (Nozzle) entries because those exact nomenclatures will be “key” to extract nominal thickness values from extraneous tables in the nozzle calculations. The C type components however do not need to have any entries in this column unless the component was made of a pipe product and even then it is optional. The [Pipe Size / Thk Reference per CML]


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button can be used to retrieve Nozzle OD size and Schedule information relative to the specific size selected per N type CML's. To use this function place curser in the CML line (anywhere) of the nozzle of interest and click the [Pipe Size / Thk Reference per CML] button. A pop up screen will appear with the pipe size in that CML line to offer you a choice of sizes/thickness. The [Pipe Size] at the top offers than same except it does not come with the size already selected which in turn means the user must select the size.

The “C-Comp ID / N-Attach Comp” column has a pick list relative to the component ID as they are designated on the PV Report Base Page and subsequently in the global table in the upper right hand corner. For the C type components select the component that the CML’s and “Component Disc” relate to (i.e CML 2 - Vessel Shell = Shell 1 therefore Shell 1 is selected) For the N type (Nozzles), select the component that the nozzle is attached too (i.e if nozzle “N2” is located in the top head select “Head 1”). This is very important as the designation will be used in the nozzle minimum thickness evaluation in the nozzle calculation form.

The “Material Spec” column has a pick list of materials most commonly uses in industry to choose from. If the list does not have the material of your choice, the list can be update via the [Material Spec] from the [Engineering Data] button found on the Front page or the API-510 PV Insp. page (lower left corner). The N Type components must have this cell populated as the stress values used in the nozzle calculations are based on the material chosen. There is an option “CS Unknown (A285 C)” that can be used in cases as specified in API-510 where the original spec. can not be determined for C Type CS components. Where the original spec. can not be determined for N type (nozzle) CS components, use “CS - A106 B”.

Entries into the CML records may be entered by adding one line at

a time or once the first one is entered the user may duplicate that one equal to the amount of CML points or number of like components and then editing CML numbers and data as needed. The later is quicker and easier.

After all the CML line entries are completed, click on the [TML Data Entry] button to enter thickness measurements. Each CML can receive up to 4 tml points (but may be less) to accommodate 4 quadrants of cylindrical type components. The last entry under the “tact” column is automatically selected and updated as the user enters the tml’s. This


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value is used to calculate the corrosion rates and remaining life. That entry is normally the lowest reading of that CML (tml set). Note that the CML descriptions appear at the top of the form to identify what CML is being edited. Close this data form when completed to return to the Component CML Sub form.

At this point the user must make a determination as to the actual thickness value to be entered in the “Actual Thickness (t act)” section at the top of the form for each component of which the program will automatically select the lowest measurement for that component ID. Normally, regardless of the location on the component, the lowest of the tact values for that component is the value to be entered into the associated data cell in the “Actual Thickness (t act)” section. If there is a corroded section that has been evaluated for hoop stress, the resulting average thickness may be entered in place of the lowest reading.

Much of the numerical data entered in this sub form will be used hitherto in the calculation sub forms, therefore enter all numerical data as specified. The “tml” values must be entered specifically using at least the ones place (enter 0 if below 1”) and to the thousandths place for a professional appearance in the final report (i.e. x.xxx [0.500] not .xx or x.x).

The [Edit Component Data] or [Edit CML] buttons are available to edit values or text in the report if a value was entered erroneously and needs to be deleted from the cell or an alternate value is required with less placements.




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Report Shell Calculations

Figure PV-13. Cylindrical Shell Calculations

To access the Cylindrical Shell Calculations page from the front page, choose [API-510 PV Insp ] then click on [Report Builder] button at bottom of page. Choose [New Report] or [Select Existing Report] from the popup screen, then select [Open Simple PV Report] or [Open Complex PV Report]. From the Report Builder base page click on the [Cylindrical Shell Calculations] button at the bottom.

Begin performing Shell Calculations by entering required data in white cells as called for. All cells must have an entry except the secondary chamber. If there is no “distinguishing entries” required then secondary chamber cells should remain empty, however if they are required then all the cells must be filled in.



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Figure PV-14. Liquid Level for Static Head (SH) Determination

The Static Height (SH) value is normally the tank liquid operating level height (in feet) from the bottom shell weld of a vertical vessel (or bottom of corroded area of interest where localized corrosion is being evaluated), if the vessel has a liquid operating level. If the vessel is used in gaseous service the SH value is “0”. Horizontal vessels “SH” would be the height (in feet) from the bottom most elevation up to the operating liquid level along an axis in the diametric center of the cylinder cross section. Enter the Specific Gravity (SG) of the product. If SG is unknown use 1.0 in the calculation.


Material Selection - The material selection accesses a material list based ASME Section 2 Part D stress values but other material may be entered. Select the material of interest from the pull down menu (the pull down menu must be used in order to auto populate the stress (S) value). If a material not on the default list is to be used then you can ether enter in the new material in the (Material) cell and the associated material stress value can be entered in under the default stress (S) cell or preferably, you should enter the material and associated specifications into the materials module via the [Engineering Data]/[Material] buttons.

Stress (S) Values - Clicking on the [98 S] or [00 S] button will access the programs material stress sub tables which base it stress values on ASME Sect 2 Part D. The [98 S] button will access the 4x safety factor stress used to design pressure vessels before 1999. The [00 S] will access the 3.5x safety factor stress values used to design pressure vessels after the change in the ASME 1999 addenda. (user should use the


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stress value used in the design of the vessel as referenced on the Mfg U1 data sheet). User must note the material “S” associated with the design temperatures.

NOTE 1: the “S” value will default to the stress values at temperature of material selected for the year the vessel was built but may be overwritten by a user defined stress value if different from the default “S” Variable. NOTE 2: API-510 allows the use of the most current code values for use in corrosion calculations, therefore, if a vessel tmin or remaining life value results in limited or expired remaining life based on the original “S” values concluded from the “98 S” tables the user may alternately use the “00 S” value at temperature to gain some operating time on the vessel if the vessel meets the criteria of API-510 7.3 and Figure 8-1 for rerating. The Joint Efficiency (E) can be determined from the U1 data

sheet or the vessel nameplate. The [Table 12] button below the first calculation is available to assist in determining the “E” value based on configuration and degree of RT. Also user can refer to the program API-510 Insp. Module base page and click on the [Welding] button at the bottom for more specific details of code requirements for determining joint efficiencies.

For Complex PV Reports: Complex PV reports require additional data retrieval and entry. Vessels that are rated for full vacuum (denoted on the U1 for as FV

in the MAWP line) should have a value of 15 entered into the “Vac PSI” (normal atmospheric pressure is 29.9 wc (inches of Water Column) which equals to 14.7 psi and therefore a full vacuum would produce 14.7psi (rounded to 15 psi) of external pressure on the vessel.

The “Design Pa” considers the sum of Design Int. Vacuum (ext. psi) + Jacket MAWP (PSI) if applicable (i.e., not in the case of half pipe, dimpled or other type jacket that does not place a uniform force over a significant area of the shell). Select the appropriate condition form he pull down list.

Calculating minimum thickness requirements for external pressures for cylindrical type components i.a.w. ASME Section VIII, Division 1, requires making several iterations using estimated thicknesses and solving for Pa (external pressure) referencing external pressure charts (X-Charts) as follows:

1) Determine value L where L = the most critical length (the longest unsupported span) between lines of support along the longitudinal axis of a cylindrical component (i.e. Shell, Nozzle, Boot, et.). Lines of support include any point along the vessel shell that gives it inherent strength (additional strength in the girth) to resist collapsing such as compression rings, flanges, jacket tie-ins and 1/3 of the vessel heads measure from the head tangent as illustrated below in Figure PV 13


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Figure PV-15. Length L Determination

2) Determine starting value t where t = the minimum thickness (tmin) for the vessel part under consideration required to resist external pressures. The program will automatically default to the tmin required for internal pressures (where E=1) as the starting value for this iteration when clicking the [Start Iteration] button. the tmin can not be less that that required for internal pressure.

3) Applicable XChart - The Applicable X-Chart will populate the

X-Chart Cell based on the material chosen. The user has the option of viewing the material data form to verify information associated with that material. Click on [Material] button below the calculation (if error message pop ups click [refresh] button and retry). This will bring up the related material spec from which the user must note the applicable XChart (to the right of the spec. form). The referenced X-Chart can be overwritten by inputting new Chart ID in the user defined cell below the default cell.


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Figure PV-16. External thickness Calculations

4) Determine value A . The Value for variable A is determined from the applicable X Chart – Figure G (1 or 2) using the resulting L/Do and Do/t ratio values.

a. Click on the [X-Chart] button below the calculation b. Looking at the left side Y axis of the Figure G Chart,

determine which chart to use (tab one or two) based on the L/Do value.

c. From that point (where L/Do value lands on the Y axis) move to the right in a straight line across the grid until you intersect with the applicable Do/t line (or approx location of an intermediate line between given values).

d. From that point move in a straight line down to the values given along the chart horz. axis and note that value (value A).

e. Close out the X-Charts and enter that resulting value in the A cell.

Note: Alternately, for CS material with X-Chart designations of CS-2 there is a Table with Tabulated Values to the right of the formula.


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5) Determine value B (or E) . The Value for variable B is determined from the applicable material X-Chart as previously discussed (i.e. CS-1, CS-2, HA-1, et.) and shown in the X-Chart cell above the calculation. Using the resulting A value.


b. Looking at the bottom X axis of the applicable X-Chart, locate the A value previously determined from above.


1. come up in a straight line from where A falls on the X axis to the intersection of the temperature line for which the vessel was design for or approximate location of an intermediate temperature line between given values. NOTE: User may need to discuss temperature variances in conjunction with operating pressures and conditions with the Operations Engineer to determine the appropriate temperature value if the Vessel and Jacket temperature ratings vary or if the vessels operates at a significantly lower temperature than what the vessel was rated for.

2. From that point move in a straight line across to the values given along the applicable X-Chart right side Y axis and note that value (value B).




calculations. 3. Select the material type


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4. Note the value at temperature (these value are in Millions of PSI where 29 is entered into the E cell as “29000000”)


6) Calculated results and Iterations. a. If the resulting calculated Pa value is greater than or

equal to the design Pa, the results will show as satisfactory and the calculated Pa cell will display a green background.


Click the [Update Report] button at top of the form to ensure the

calculation has access to all the new and updated information and is uploaded to the Global database.

Remaining life and Internal MAWP will be automatically calculated. User defined cells are available to the user if extenuating conditions dictate that alternative values would be more fitting. When ever updates are made or user defined options are exercised, the [Update Calcs] buttons should be click.

Prior to exiting or printing the [Refresh] and the [Update Report] buttons should be click to ensure all calculations were performed and that updated information goes to the global database for use in other forms such as the head calculations and the Executive Summary TABLE A.

To the right of the minimum thickness calculations is an additional minimum required thickness (tmin) calculation based on an E value of 1 that should be used when doing nozzle tmin, reinforcement (tr value) and hoop stress calculations for localized corroded areas more than an inch away from any weld seam. This value will be exported to the global data when the [Update Report] button is clicked to be used in the subsequent nozzle tmin evaluation.

To print, ensure to click the [Refresh] and the [Update Report] then click the print preview icon (page w/ magnifying glass) in upper right hand corner then select print from the preview page. DO NOT print from the data input form. NOTE: Click on save icon in upper right hand corner before selecting print preview.


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Where there are circumstances that require the use of an alternate tmin, (i.e. using the nominal minus the corrosion allowance to determine tmin) the user may enter that value in the yellow cell under user defined tmin in the remaining life box. This value will override the calculated tmin.

Where there are circumstances that require the use of an alternate corrosion rate, (i.e. a new component using previously determined corrosion rate) the user may enter that value in the yellow cell under user defined Cr in the remaining life box. This value will override the calculated corrosion rate and result in a new remaining life value.

The [Shell Data Edit] and the [CML] buttons are available to edit the CML data if a value was entered erroneously and needs to be deleted from the cell or an alternate value is required.

Report Head Calculations

Figure PV-17. Formed Head Calculations

To access the Head Calculations page from the front page, choose [API-510 PV Insp] then click on [Report Builder] button at bottom of page. Choose [New Report] or [Select Existing Report] from the popup screen, then select [Open Simple PV Report] or [Open Complex PV


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Report]. From the Report Builder base page click on the [Head Calculations] button at the bottom.

Begin performing Head Calculations by entering required data in white cells as called for. All cells must have an entry except the secondary chamber. If there is no “distinguishing entries” required then secondary chamber cells should remain empty, however if they are required then all the cells must be filled in.


Figure PV-18. Liquid Level for Static Head (SH) Determination

The Static Height (SH) value is normally the tank liquid operating level height (in feet) from the bottom most elevation of the head of interest of a vertical vessel (or bottom of corroded area of interest where localized corrosion is being evaluated), if the vessel has a liquid operating level. If the vessel is used in gaseous service the SH value is “0”. Horizontal vessels “SH” would be the height (in feet) from the bottom most elevation up to the operating liquid level along an axis in the diametric center of the cylinder cross section. Enter the Specific Gravity (SG) of the product. If SG is unknown use 1.0 in the calculation.

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Material Selection - The material selection accesses a material list based ASME Section 2 Part D stress values but other material may be entered. Select the material of interest from the pull down menu (the pull down menu must be used in order to auto populate the stress (S) value). If a material not on the default list is used then you can ether enter in the new material in the (Material) cell and the associated material stress value can be entered in under the default stress (S) cell or you can enter the material and associate specifications into the materials module via the Engineering Data/Material button.

Stress (S) Values - Clicking on the [98 S] or [00 S] button will access the programs material stress sub tables which base it stress values on ASME Sect 2 Part D. The [98 S] button will access the 4x safety factor stress used to design pressure vessels before 1999. The [00 S] will access the 3.5x safety factor stress values used to design pressure vessels after the change in the ASME 1999 addenda. (user should use the stress value used in the design of the vessel as referenced on the Mfg U1 data sheet). User must note the material “S” associated with the design temperatures.

NOTE 1: the “S” value will default to the stress values at temperature of material selected for the year the vessel was built but may be overwritten by a user defined stress value if different from the default “S” Variable. NOTE 2: API-510 allows the use of the most current code values for use in corrosion calculations, therefore, if a vessel tmin or remaining life value results in limited or expired remaining life based on the original “S” values concluded from the “98 S” tables the user may alternately use the “00 S” value at temperature to gain some operating time on the vessel if the vessel meets the criteria of API-510 7.3 and Figure 8-1 for rerating. The Joint Efficiency (E) can be determined from the U1 data

sheet or the vessel nameplate. The [Table 12] button below the first calculation is available to assist in determining the “E” value based on configuration and degree of RT. Also user can refer to the program API-510 Insp. Module base page and click on the [Welding] button at the bottom for more specific details of code requirements for determining joint efficiencies.

NOTE: For seamless heads code requirements, E = 1.0 when vessel is stamped RT-1 or RT 2. E = 0.85 when the radiographic exam does not meet the requirements for RT 1 or 2 stamping, or when the Category A or B welds connecting seamless vessel components or heads are Type No. 3, 4, 5, or 6 of table UW-12.


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Sidebar: it is of note that many existing pressure vessel were designed where E = 1 for the seamless heads regardless of RT values…

For Complex PV Reports: Complex PV reports require additional data retrieval and entry. Vessels that are rated for full vacuum (denoted on the U1 for as FV

in the MAWP line) should have a value of 15 entered into the “Vac PSI” (normal atmospheric pressure is 29.9 wc (inches of Water Column) which equals to 14.7 psi and therefore a full vacuum would produce 14.7psi (rounded to 15 psi) of external pressure on the vessel.

The “Design Pa” defaults to the sum of Design Int. Vac (ext. psi) + Jacket MAWP (PSI).


1) Determine values L & R - L = the inside spherical or crown

radius of the head under consideration, in inches and r = inside knuckle radius, in inches.. These values are automatically determined by the program except for the Torispherical values of which can be obtained from the U1 data sheet.

2) Determine starting value t where t = the minimum thickness

(tmin) for the vessel part under consideration required to resist external pressures. Click the [Start Iteration] button above the Head 1 “t” variable in the external calculation boxes. The program will automatically default to the tmin required for internal pressures (where E=1) as this value can not be less that that required for internal pressure.

NOTE: Do not click the [Start Iteration] button once the iteration process has begun as it will re-insert the starting thickness. 3) Applicable XChart - The Applicable X-Chart will populate the

X-Chart Cell based on the material chosen. The user has the option of viewing the material data form to verify information associated with that material. Click on [Material] button below the calculation (if error message pop ups click [refresh] button and retry). This will bring up the related material spec from which the user must note the applicable XChart (to the right of the spec. form). The referenced X-Chart can be overwritten by inputting new Chart ID in the user defined cell below the default cell.


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Figure PV-19. External Thickness Calculations for Heads

4) Determine value B (or E) . The Value for variable B is determined from the applicable material X-Chart as previously discussed (i.e. CS-1, CS-2, HA-1, et.) and shown in the X-Chart cell above the calculation. Using the resulting A value.


b. Looking at the bottom X axis of the applicable X-Chart, locate the A value.


1. come up in a straight line from where A falls on the X axis to the intersection of the temperature line for which the vessel was


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design for or approximate location of an intermediate temperature line between given values. NOTE: User may need to discuss temperature variances in conjunction with operating pressures and conditions with the Operations Engineer to determine the appropriate temperature value if the Vessel and Jacket temperature ratings vary or if the vessels operates at a significantly lower temperature than what the vessel was rated for.

2. From that point move in straight line across to the values given along the applicable X-Chart right side Y axis and note that value (value B).




calculations. 3. Select the material type 4. Note the value at temperature (these value

are in Millions of PSI where 29 is entered into the E cell as “29000000”)


6. 5) Calculated results and Iterations.




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Click the [Update Report] button at top of the form to ensure the

calculation has access to all the new and updated information and is uploaded to the Global database.

Remaining life and Internal MAWP will be automatically calculated. User defined cells are available to the user if extenuating conditions dictate that alternative values would be more fitting. When ever updates are made or user defined options are exercised, the [Update Calcs] buttons should be click.

Prior to exiting or printing the [Refresh] and the [Update Report] buttons should be click to ensure all calculations were performed and that, that information goes to the global database for use in other forms such as the head calculations and the Executive Summary TABLE A.

To the right of the minimum thickness calculations is an additional minimum required thickness (tmin) calculation based on an E value of 1 that should be used when doing nozzle tmin, reinforcement (tr value) and hoop stress calculations for localized corroded areas more than an inch away from any weld seam. This value will be exported to the global data when the [Update Report] button is clicked to be used in the subsequent nozzle tmin evaluation.

To print, ensure to click the [Refresh] and the [Update Report] then click the print preview icon (page w/ magnifying glass) in upper right hand corner then select print from the preview page. NOTE: Click on save icon in upper right hand corner before selecting print preview.

Where there are circumstances that require the use of an alternate tmin, (i.e. using the nominal minus the corrosion allowance to determine tmin) the user may enter that value in the yellow cell under user defined tmin in the remaining life box. This value will override the calculated tmin.

Where there are circumstances that require the use of an alternate corrosion rate, (i.e. a new component using previously determined corrosion rate) the user may enter that value in the yellow cell under user defined Cr in the remaining life box. This value will override the calculated corrosion rate and result in a new remaining life value.

The [Edit Head Data] and the [CML] buttons are available to edit the CML data if a value was entered erroneously and needs to be deleted from the cell or an alternate value is required.


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Report Nozzle Calculations

Figure PV-20. Nozzle Calculations

To access the Nozzle Calculations page from the front page, choose [API-510 PV Insp ] then click on [Report Builder] button at bottom of page. Choose [Select Existing Report] from the popup screen, then select [Open Simple PV Report] or [Open Complex PV Report] as signified. From the Report Builder base page click on the [Nozzle Calculations] button at the bottom.

Nozzle evaluations are presented in this sub form based on previous data entry and minimum thicknesses as recommended in ASME Sect VIII, UG-45 for nozzle tmins as follows:

a. Standard pipe thicknesses minus 12.5% or b. Connecting shell/head required thickness, whichever is

smaller. c. Large size nozzles or nozzles subject to high pressures are

calculated per ASME Sect VIII, DIV 1, UG-27 as follows: PR/SE-0.6P = t. when the resulting tmin is greater than results of the a or b choice above.


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The default values are automatically entered as the user places the curser in the open tprev and tmin cell of each CML line. The default tprev and tmin values can be over ridden by simply typing the new value in the cell. The [Edit CML] button is available to edit the CML data if a value was entered erroneously and needs to be deleted from the cell or an alternate value is required with less placements.

The calculation at the bottom is relative to the CML line that the curser is placed in. User defined cells are available for any value that may need to be updated.

A [NPS per Noz ID] button is available for a quick reference to the pipe size for the size nozzle that is selected. Click on the CML of interest then click the [NPS per Noz ID] button in the top right corner to view OD and pipe schedules/wall thickness for that Nozzle size. Note that the selection pull down does not work in this mode.

A [Nozzle Standards] button is available for a quick reference to all pipe/nozzle data. Click on the [Nozzle Standards] button then select the subject matter of interest.

The [Global Insp Data] button is available to update the next inspection intervals if any of the nozzle appear to govern the inspection frequency and also to view basic data that to assist in information flow.


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Figure PV-21. Write-up and Recommendations

To access the Write-up and Recommendations page from the front page, choose [API 510 Insp.] then click on [Report Builder] button at bottom of page. Choose [Select Existing Report] from the popup screen, then Click on the [Inspection Report Write-up] button at the bottom.

The [Codes] button is available for quick access to referencing codes.



Cells across the top are for referencing dates for next inspections intervals and governing component. The governing component is normally the component with the least remaining life.

The “Years to Next Insp”. is a reference to the next UT inspection for determining corrosion rates is normally 10 years.


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The Executive Summary (ES) text comes in with a default text that needs to be edited to reflect associated information. Alternately, the user may delete the default text and enter other text as desired. Normally the only discrepancies that make it into the Executive Summary are the items with a significant cost value or issues that are causing some limitation to the operating parameters of the Tank. These items should be in the body of the report and can easily be copied and pasted into the ES with some minor editing.

To do a spell check, place the curser within top left of the write-up text windows or highlight the text of the ES text window, (the two sections must be checked separately) and click F7 on the key board.



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Report PV Checklists

Figure PV-22. Report PV Checklists

To access the Report Component CML Data Form from the front page, choose [API-510 PV Insp ] then click on [Report Builder] button at bottom of page. Choose [New Report] or Select [Existing Report] from the popup screen, then select [Open Simple PV Report] or [Open Complex PV Report]. From the Report Builder base page click on the [API-510 Checklists] button at the bottom.

Scroll through the list and enter an X in the cell of the line for the relevant items that were checked during the inspection and type X [Caps])



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NDE Forms: (reference API 653 Module / NDE Forms Previously reviewed) Supplementary Calculations: (reference Engineering Data / Calculations Previously reviewed) Report AutoCAD PV Inspection Drawings

Figure PV-23. AutoCAD Shell Ledger Drawing


User must obtain the field data sheet and drawing(s) relative to this project.

To access the PV Cad Drawings page from the front page, choose [API-510 PV Insp ] then click on [Report Builder] button at bottom of page. Choose [Select Existing Report] from the popup screen, then select [Open Simple PV Report] or [Open Complex PV Report]. From the Report Builder base page click on the [PV Cad Drawings] button at the bottom right, then click the [Vessel.dwg] link to the AutoCAD template. Save the


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file to the a project folder and pint out the Ledger drawing for reference when building the shell drawing.



2) In model space (MS enter on command line), On command line: a. Command: insert “Vert” or “Horz” b. Insertion Point: “0,0” c. X scale factor: enter default d. Y scale factor: enter default e. Rotation Angle: enter default. f. Command: Zoom to limits (if this does not bring the shell into a full view then zoom to a scale to gain a full view) g. Explode Vert. Block h. Edit the drawing to reflect the design of the PV of interest.


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Reference the shell template drawing for “to scale” blocks (such as manways, nozzles, platforms, et.) available to user to modify the Vertical or Horizontal templates. Photos and Other Files: (reference API 653 Module / API-653 Report Builder / Photos and Other Files Previously reviewed)


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API 570 Piping Inspection Module API 570 PV Inspection Module Main Page

API 570 PV Module can only be accessed from the Front Page API 570 PV Module is laid out to help you find information quickly


Figure PPG-1. API 570 PV Inspection Module Main Page

The tabulated text windows are designed to facility quick access to information that an Inspector or Reliability Engineer may need in response to questions or inspection findings that require timely judgment calls. The subject matters are broken down into various headings such as Inspection Intervals, Pipe Design, Pipe Inspection, etc. to facilitate a more user friendly navigation to information and quick answers to questions. These component text windows have subsets of pages addressing the various disciplines related to assessing the mechanical integrity of in-service piping systems in accordance with code requirements. The disciplines


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include design criterion, inspection guidelines for assessing degradation, repair specifications for each of the components, code requirements for testing in-service and repaired components.

Procedure for viewing/seeking text window subject matter: 1) Pick on subject tab of interest (Inspection Intervals, Piping

Repair, NDE Testing, Pressure Relief, etc.). 2) Click in window of interest to activate vertical scroll. 3) Click on arrow button below subject tab (or at bottom of window)

to scroll to sub text of choice. 4) Use vertical scroll in text window (not vertical page scroll) to

peruse the subject matter or reference being sought. Under each of the tabulated subjects are subset pages with both


II. Visual and NDE inspection and evaluation: A. Corrosion deterioration 1. Piping sections with corroded areas that do not meet minimum thickness requirements must be repaired or replaced. 2. Piping sections that do not meet minimum thickness requirements must be replaced. B. Weld Joints 1. Acceptance criteria for indications. a. reference Table 341.3.2 of ASME B31.3 b. in-service inspection that do not meet the acceptance criteria of Table 341.3.2 to be evaluated by pipe engineer on a case by case basis. C. Guide to Quantifying Corrosion 1. General - Spread throughout the component surface area. Erosion/Corrosion/Pitting covering >10% of the surface area with wall thickness loss <0.050". May have a rough or smooth cohesive surface profile.


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Figure PPG-2. Tabulated Subject Text Windows


buttons linked to the most commonly associated Codes (API-570, ASME-B31.3, ASME Section V, etc.) in PDF format to provide quick access to those codes when needed. (No laboring or searching) along with a “Codes” button that will navigate you to additional API, ASME and other associated codes as well.



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Engineering Data: (reference section for Engineering Data previously reviewed)

Repair Specifications: (reference API 653 Module / Repair Specifications previously reviewed)

Inspection Forms (Field Forms)

Field data inspection forms can be accessed from the [Inspection Forms] button at the bottom of the API-570 Pipe Inspection Module. To access the Inspection Forms from the front page choose [API-570 Pipe Insp] then click on [Inspection Forms] button at bottom of page then click on Inspection form(s) required for the scope of inspection (API 570 Checklist, Piping CML Record Form, Iso drawing template, et).

To print, select print from the preview page. AVAILABLE FORMS: API 570 Field Data Sheet:

Figure PPG-3 . Piping Field Data Sheet


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API 570 Checklists:

Figure PPG-4 . API-570 Piping Field Checklist

1. Recommended to fill out one checklist per iso drawing.


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Piping TML Record Form :

Figure PPG-5 . Piping TML Record Form

1. Start by designating a numbering system on the iso drawing and

then number the CML’s on the record form in sequence to match the iso’s. Iso’s should be numbered in a sequence to flow with linking segments of the piping system and be numbered continuously (not starting over from 1 every iso)

2. Component line numbers should be recorded as established by the client and organized in a systematic system following source to target from header, mainline, then subsequent sequence in accordance to flow as much as possible. (different systems/circuits can be listed together as long as they are grouped together and have distinguishing CML numbers (ID’s) otherwise start a new form to segregate them).

3. Size should be entered in accordance with nominal reference to diameter (i.e. 2, 4, 8, 10, et.)

4. Component description is a reference to the component physical configuration such as Straight Pipe, T-Fitting, Elbow 90°, . Elbow 45°, et.

5. TML’s should be recorded for all 4 quadrants of the CML if possible. The order for referenced location is as follows:

a. Components with Vert. Axis: tml-1 N., tml-2 E., tml-3 S., tml-4W.


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b. Components with Horz. Axis: tml-1 Top, tml-2 Side, tml-3 Bttm, tml-4 Side (Clockwise looking with the flow)

Piping Iso drawings :

Figure PPG-6 . Pipe Iso Drawing Sheet


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NDE Inspection forms (reference section for API-653 Module/Inspection Forms previously reviewed)

PV Hydrostatic (Hydro) Test Calculations

Figure PPG-7. Hydro Test Calculation Data Entry Form

The Piping Hydrostatic Test calculations can be accessed from the API 570 Piping Inspection Module. To access the Pipe Hydro Test calculations from the front page choose [API 570 Pipe Insp.] then click on [Hydro Test] button at bottom of page.

Begin performing Pipe Hydro Test calculations by clicking the [+] icon at the top right hand corner and entering data in cells as called for.


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The material selection accesses a material list from ASME B31.3 specifications but other material may be entered. If a material not on the default list is used then the material stress will have to be entered manually.

Clicking on the [B31.3 Table] button will access the programs material stress sub tables which bases it’s stress values on ASME B31.3 Table A. New material not found in the selection may be entered in this table to be accessed from the pull down and be available for future use. User must note the material “S” associated with the ambient and design temperatures. Note the “S” Amb and Temp will default to the stress/temperature value of material selected but may be overwritten by user.

Note that as the user scrolls down the form, both the Hydrostatic and pneumatic test pressures and the reduced exam pressure are calculated along with guidelines to the process.

Figure PPG-8. Hydro Test Data Entry Form

Click on the [Hydro Test Report] button at the top left of the page to fill out a test record form. Users can fill in the form with available information and specifications (Design Pressure, Design Temp, Hold Time, etc.) prior to Hydro testing to be issued to the responsible party


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directing the hydro. The responsible party directing the hyrdo is to complete the record with the actual event data (Actual Test pressure, Start Time/Date, End Time/Date, etc.). Once the record is returned to the user, the remaining outstanding data can be entered and the record reissue for signatures for hard copy file.

Notes may be entered in the comments section if necessary at the bottom of the data cells. Notes will appear in the comments section of the report.

To print, click the print preview icon (page w/ magnifying glass) in upper right hand corner of the test form then select print from the preview page. NOTE: Click on save icon in upper right hand corner before selecting print preview. Note that the second page has the steps and target pressures if a pneumatic pressure test is opted.

Figure PPG-9. Hydro Test Record


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Figure PPG-10. API 570 Inspection Report Builder Data Entry Form

To access the API 570 Inspection Report Builder from the front page choose [API 570 Pipe Insp.] then click on [Report Builder] button at bottom of page. Choose [New Report] or [Select Existing Report] from the popup screen.

Choosing [New Report] and enter a “Report No.” and then click [Start New Report].

The report should be configured at this point. Pick the [Configure/ Report Appendix] bottom at the bottom left. Select the Appendix A pull down and select Appendix A…the report will then be configured…close the Appendix page to get back to the API-570 Report Builder base page.

Begin report by entering data in cells as called for. Much of the numerical data entered on the report builder front page

will be used in the calculations of sub forms, therefore enter all numerical data as specified without signifiers (i.e., “Design Pressure” should be enter as 1550 not 1550psi).


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The Age/Prev Insp. is a number not a date (i.e., 9, 20, 34, et) which will be used to calculate corrosion rates, therefore the “Nominal Thickness” value must correspond with the “Age/Prev Insp” value.

Entry data cells with [*] buttons next to them allows for additions to be entered for use in pull down menus that are not available. (i.e. Inspector or Service). This allows the user to build the data base with data for future access and use.

A link to the PDF Codes/Standards library is available at the top of the form for quick access to the codes that the user may entered in the system.

A link to the supplemental pipe calculations is available where additional calculations may be needed. Click on [Pipe Calculations] at the bottom and then select the calculation of interest.

The cover page of the report comes with a default standard introductory text that that can be edited as the user desires.


The data entry on the main page has some pull downs for selecting the API class and ASME Category for the piping system. If unsure of the selection please refer to the API-570 Module Base page under the Text Window tabbed “Inspection intervals” and Text Window tabbed “Pipe Design” for definitions and as follows

1. Pipe Service Classes from API-570 Piping Inspection Code; API Class 1 Services with the highest potential of resulting in an immediate

emergency if a leak were to occur are in Class 1. Such an emergency may be safety or environmental in nature. Examples of Class 1 piping include, but are not necessarily limited to, those containing the following:

a. Flammable services that may auto-refrigerate and lead to brittle fracture.

b. Pressurized services that may rapidly vaporize during release, creating vapors that may collect and form an explosive mixture, such as C2, C3, and C4 streams. Fluids that will rapidly vaporize are those with atmospheric boiling temperatures below 50°F (10°C).

c. Hydrogen sulfide (greater than 3 percent weight) in a gaseous stream.

d. Anhydrous hydrogen chloride. e. Hydrofluoric acid. f. Piping over or adjacent to water and piping over public

throughways. (Refer to Department of transportation and U.S. Coast Guard regulations for inspection of over water piping.)

API Class 2


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Services not included in other classes are in Class 2. This classification includes the majority of unit process piping and selected off-site piping. Typical examples of these services include those containing the following:

a. On-site hydrocarbons that will slowly vaporize during release such as those operating below the flash point.

b. Hydrogen, fuel gas, and natural gas. c. On-site strong acids and caustics. API Class 3 Services that are flammable but do not significantly vaporize when

they leak and are not located in high-activity areas are in Class 3. Services that are potentially harmful to human tissue but are located in remote areas may be included in this class. Examples of Class 3 service are as follows:

a. On-site hydrocarbons that will not significantly vaporize during release such as those operating below the flash point.

b. Distillate and product lines to and from storage and loading. c. Off-site acids and caustics. 2. Pipe Service Category from ASME B31.3 Piping design code; A. Category D fluid service - a fluid service that is non-flammable, non-toxic, and not damaging to human tissue, not in excess of 150psi or 366°F. B. Category M fluid service - a fluid service where a small quantity caused by a leak would cause irreversible harm to persons upon breathing or bodily contact. C. Normal fluid service - a fluid service not subject to the rules for category D or M, or in high pressure service or cyclic service conditions. As the user scrolls down the base page there is a “Pipe/Nozzle

Practical tmins” table that will come up. These values default to the program practical tmin values but can be over written by the user. These values will be used throughout the program when evaluation the remaining life of the piping components.

Once all the front page data cells are populated the user can proceed to the sub forms for Data Evaluations, Write-ups, Recommendations and other report building functions. The user should always progress from left to right when entering data in sub forms as the program cascades information as the report is progressed.


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Report Appendix must have an initial entry to run the base page report preview (blank report will come up otherwise). The front page report preview page is limited to the fist four pages of the report.


preview icon (page w/ magnifying glass) in upper mid section then select print from the preview page. NOTE: Click on save icon in upper right hand corner before selecting print preview. Note also that the Executive Summary does not conform to the report until updates are made in the “Inspection Results Writeup” Subform.

To print the finished Report, click the (green) Report Icon and click print. This will print the front page and the sub forms from left to right up to the “API-570 Checklists”. Any supplemental documents (such as Extraneous Calculations, NDE Reports, Photographs, Drawings, etc.) must be printed independently. Once the Report is printed it must be assembled inserting the Appendix documents in the associated appendix sections.

The [File Table Edit] is available to use when a user has several reports that have repetitive information and desires to duplicate a report to edit data that is different from the originating report. Click on the [File Table Edit] button, right click on the left of the report desiring to duplicate, Pick ”Copy”, Right click on the blank field at the bottom of list. Pick “Paste”. This will copy all the front page and subpage data text fields. It does not copy the CML/TML data. Immediately change the report (also user can edit other data in this mode as well). Close this entry form and click on the [Select Existing Report] button and open the new report to continue editing/building the report.



The report automatically places a signature text for the Inspector on the front page and his signature in Paint Brush format (.bmp) may be inserted into the report at the bottom right “signature” cell. The material selection found throughout the Report Module will accesses a material list based on specifications from ASME B31.3.

A record may be deleted by clicking the red “ال” icon at the top right hand corner and confirming. User should delete all sub form files


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prior to performing this function on the base page (initial API-570 data entry page).

Import/Export buttons are provided to transfer data from one API

Toolbox program to another. There are 4 basic data sets associated with the report that must be transferred.

10. Base Page Report Data 11. Report Appendices 12. CML Record 13. API-570 Checklist


Procedure for transferring data: 1) Create a transfer file folder for temporary file storage in source PC (i.e, inspector’s field laptop). 2) Export all the following data sets for the report of interest from the API Toolbox Report Builder and sub forms to the designated transfer file folder. (do not rename files) a. Report Builder Base Page b. Report Appendices c. CML Record d. API-510 Checklist 3) Save files from the source transfer folder to a transfer medium (i.e. USB Storage, CD) or attach files to email for delivery to destination PC/ API Toolbox program. 4) In the destination PC (i.e,. the technical writer’s PC), create a transfer file folder for temporary file storage. 5) In the destination API Toolbox program, open a random report in the Report Builder and export all data sets, as instructed in step 2 above, to the transfer file folder. (this is done to enable the import command to target a folder to retrieve the data sets from (do not rename of files).


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6) Delete the exported excel data files from the transfer folder and then copy the source excel data files from the transfer medium or email into the transfer folder. (do not rename files) 7) From the destination PC/ API Toolbox random report, Import the following data sets. (caution: ensure that the files to be imported have a unique report number from any existing report or the reports will be merged and cause printing errors) a. Report Builder Base Page b. Report Appendices c. CML Record d. API-510 Checklist 8) Click the [Select Existing Report] button, find the newly imported report and open 9) Report write-up paragraphs will need to be re-spaced.


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Config. / Report Appendix

Figure PPG-11. Report Appendix Builder

To access the Configure / Report Appendix page from the front page, choose [API-570 Piping Insp ] then click on [Report Builder] button at bottom of page. Choose [New Report] or [Select Existing Report] from the popup screen, then select [Open Report] then from the Report Builder base page click on the [Configure / Report Appendix] button at the bottom left.






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Report Component Corrosion Monitoring Location (CML) Record

Figure PPG-12. Component CML Data Entry Form

To access the Report Component CML Data Form from the front page, choose [API-570 Pipe Insp ] then click on [Report Builder] button at bottom of page. Choose [New Report] or Select [Existing Report] from the popup screen, then select [Open Report]. From the Report Builder base page click on the [CML Record] button on the left.

Begin entering data in cells in the “Pipe CML Record” data section as called for.


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The CML must be entered by the user in sequence (as completed on the field forms) using three digit entries (i.e., 001, 002, 003)

“Line No” Component line numbers should be entered into the program as recorded on the field data sheet as established by the client and organized in a systematic system following source to target from header, mainline, then subsequent sequence in accordance to flow as much as possible. (different systems/circuits can be listed together as long as they are grouped together and have distinguishing CML numbers (ID’s) otherwise start a new form to segregate them).

The “Age” cell will default to the Age as entered on the Base page but can be over written if the component was subsequently replaced and has a different age value.

The “Material-Grade” column has a pick list of materials most commonly uses in industry to choose from. The Material must be selected from the pull down for the program to automatically fill in the stress value at temperature in the calculation page to calculate the minimum required thickness.

The “Size” should be entered in accordance with nominal reference to diameter (i.e. 2, 4, 8, 10, et.) from the pull down menu.

The “Sch” (schedule) should be selected and entered in accordance with associated thickness of the piping system of interest from the pull down menu.

The “Comp Desc” is a reference to the component physical configuration such as Straight Pipe, T-Fitting, Elbow 90°, . Elbow 45°, et.

The “E” (joint quality factor) will default to 1 but may be overwritten at the user’s desire.

Entries into the CML records may be entered by adding one line at

a time or once the first one is entered the user may duplicate that one equal to the amount of CML points or number of like components and then editing CML numbers and data as needed. The later is quicker and easier.

After all the CML line entries are completed, click on the [TML Data Entry] button to enter thickness measurements. Each CML can receive up to 4 tml points (but may be less) to accommodate 4 quadrants of cylindrical type components. The last entry under the “tact” column is automatically selected and updated as the user enters the tml’s. This value is used to calculate the corrosion rates and remaining life. That entry is normally the lowest reading of that CML (tml set) but may be over


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written at the user’s discretion. Note that the CML descriptions appear at the top of the form to identify what CML is being edited. Close this data form when completed to return to the Component CML Sub form.

Much of the numerical data entered in this sub form will be used hitherto in the calculation sub forms, therefore enter all numerical data as specified. The “tml” values must be entered specifically using at least the ones place (enter 0 if below 1”) and to the thousandths place for a professional appearance in the final report (i.e. x.xxx [0.500] not .xx or x.x).

The [Edit CML] buttons are available to edit values or text in the report if a value was entered erroneously and needs to be deleted from the cell or an alternate value is required with less placements.




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Report Pipe Calculations

Figure PPG-13. Pipe Remaining Life Evaluations

To access the Pipe Remaining Calculations page from the front page, choose [API-570 Pipe Insp ] then click on [Report Builder] button at bottom of page. Choose [Select Existing Report] from the popup screen, then select [Open Report] as signified. From the Report Builder base page click on the [Pipe Remaining Calculations] button at the bottom.

Pipe component evaluations are presented in this sub form based on previous data entry and minimum thicknesses as recommended in API-570 for piping tmins as follows:

API-570 7.3 RETIREMENT THICKNESS DETERMINATION

Recommends establishing a greater thickness than the calculated thickness to allow for undiscovered metal loss due to general and localized corrosion, unanticipated loadings, and resistance to normal loss. These "tmins are what is referred to in the industry as a "Practical Thickness". It is up to each owner/user of the piping system to establish there own Practical thicknesses and should be based on engineering evaluations for their application. This API-570 Toolbox has established tmins based on common industry design parameters and can be found


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under Engineering Data/Pipe Standards/Practical tmins and in the upper right hand corner of this calculation page. There is a table in the API-570 Reporting module base page that can take user defined values to be used in the inspection reports evaluations as well.

The default values are automatically entered as the user places the curser in the open tprev and tmin cell of each CML line. The default tprev and tmin values can be over ridden by simply typing the new value in the cell. The [Edit CML] button is available to edit the CML data if a value was entered erroneously and needs to be deleted from the cell or an alternate value is required with less placements.

The calculation at the bottom is relative to the CML line that the curser is placed in. User defined cells are available for any value that may need to be updated.

A [Nozzle Standards] button is available for a quick reference to all pipe/nozzle data. Click on the [Nozzle Standards] button then select the subject matter of interest.

The [Global Insp Data] button is available to update the next inspection intervals if any of the nozzle appear to govern the inspection frequency and also to view basic data that to assist in information flow.


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Figure PPG-14. Write-up and Recommendations

To access the Write-up and Recommendations page from the front page, choose [API 570 Insp.] then click on [Report Builder] button at bottom of page. Choose [Select Existing Report] from the popup screen, then Click on the [Inspection Report Write-up] button at the bottom.

The [Codes] and [Pipe Standards] button is available for quick access to referencing codes and pipe standards.



Cells across the top are for referencing dates for next inspections intervals and governing component. The governing component is normally the component with the least remaining life.

The “Years to Next UT Insp”. is a reference to the next UT inspection for determining corrosion rates is normally 5 years.



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The Executive Summary (ES) text comes in with a default text that needs to be edited to reflect associated information. Alternately, the user may delete the default text and enter other text as desired. Normally the only discrepancies that make it into the Executive Summary are the items with a significant cost value or issues that are causing some limitation to the operating parameters of the system. These items should be in the body of the report and can easily be copied and pasted into the ES with some minor editing.

To do a spell check, place the curser within top left of the write-up text windows or highlight the text of the ES text window, (the two sections must be checked separately) and click F7 on the key board.



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Report Piping Checklists

Figure PPG-15. Report API-570 Checklists

To access the Report Checklist Form from the front page, choose [API-570 Pipe Insp ] then click on [Report Builder] button at bottom of page. Choose [New Report] or Select [Existing Report] from the popup screen, then select [Open Report]. From the Report Builder base page click on the [API-570 Checklists] button at the bottom.

Scroll through the list and click in the cell of the line for the relevant items that were checked during the inspection and enter any relative comments as desired.

The user may click the [New File] or [Duplicate] buttons at the top

to make as many checklists as needed (usually one per iso) and may scroll through them with the page over arrows at the top. Ensure that


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when making copies of the checklist that the Iso Drawing No and Line No references are edited to reflect the associated documents.


NDE Forms: (reference API 653 Module / NDE Forms Previously reviewed) Supplementary Calculations: (reference Engineering Data / Calculations Previously reviewed) Report AutoCAD PV Inspection Drawings

Figure PPG-16. Report Iso Drawings



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User must obtain the field data sheet and drawing(s) relative to this project.

To access the Iso Drawings page from the front page, choose [API-570 Pipe Insp ] then click on [Report Builder] button at bottom of page. Choose [Select Existing Report] from the popup screen, then select [Open Report]. From the Report Builder base page click on the [ISO DWGS] button at the bottom right, then click the [Iso Temp.dwg] link to the AutoCAD template. Save the file to the a project folder and pint out the Ledger drawing for reference when building the shell drawing.


1) Edit all title blocks and drawing text in papers space (PS ---> enter on command line) related to specific report info (Company, Date, and other text as needed to conform to user company drawing protocols).

2) The drawing comes with diverse entities for use by experienced cad drivers for building iso drawings.


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Contacts

The Contacts Module can only be accessed from the Front Page and is included in this program to make available a tool for the Inspector or Reliability Engineers to start a contacts list relative to the ongoing need to record and recall client/ venders information.

Place the curser anywhere in the line of the contact will show in the upper section in bigger and bolder display.

Single client information or company listings can be printed. The binoculars icon can be used to locate entries via a key word

search.


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API Inspectors Toolbox EE - User Guide

Documents

magnifying

external static

report builder

mt exam form

pt exam form

service inspection

selecting

update form