A Study Guide

for
Pressure Equipment Inspectors
(Part 2)

The Inspectors Calcs

Corrosion Rates
Equipment Remaining Life
Inspection Intervals
Next Inspection Date

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 How do I calculate the Remaining Life?

The Remaining Life at a specific TML is the length of time remaining until this point corrodes to the
retirement thickness. The Remaining Life is the life from date of the last thickness reading. It is not the
remaining time from todays date (unless the last reading was taken today). The Remaining Life is
basically how long until the Corrosion Bug eats through the Remaining Corrosion Allowance.

Retirement thickness is also called minimum thickness (tmin). The retirement thickness (minimum
thickness) is calculated using appropriate formulas from the construction code.

Here is the formula for Remaining Life:

Remaining Corrosion Allowance (RCA) tlast tmin

Formula #2: Remaining Life = =
Remaining Life Corrosion Rate (CR) CR

Note! The Remaining Life for an Equipment Item is based

on the TML with the lowest Remaining Life!

Illustration: Calculate Remaining Life

Here is the thickness data for TML #6. The corrosion rate at this TML is 0.005 ipy. Calculate the
Remaining Life.

Thickness Data

TML # tminimum Jan. 2004 Jan. 1994

6 0.270 0.300 0.350

tlast tmin
Life = No need to calculate the Corrosion Rate.
CR It was given in the problem.

0.300 0.270 0.030

Life = = = 6 yrs
0.005 0.005

The Equipment Life at this TML is 6 years from

the last inspection date (January 2004).

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Exercise 6: Calculate the Remaining Life
Calculate this Remaining Life for the following TML.

TML Data
TML # Corrosion Rate tminimum March 2004
D-7 0.007 ipy 0.150 0.198

Life = Remember! Always write the formula!

Life = = = yrs

Exercise 7: Another Remaining Life

Calculate this Remaining Life for the following TML.

TML Data
TML # Corrosion Rate tminimum March 2004
D-8 0.003 ipy 0.150 0.211

Life = Remember! Always write the formula!

Life = = = yrs

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 How do I determine the Inspection Interval?

Inspection Intervals are determined based on the applicable requirements from the Inspection Code.
Table-3 summarizes the current rules for setting the Inspection Intervals.

Note! When establishing the interval for most inspection types, the Remaining Life must be calculated
first. Without knowing the Remaining Life, the Interval cannot be set!

Table 3: Inspection Code Inspection Type Inspection Interval Rule

Interval Rules
API 510 - Vessels Internal a) Normally, lesser of 10 yrs or Life, or
b) 2 yrs - if Life is from 2-4 yrs, or
c) Full Life - if Life is < 2 yrs
External Lesser of 5 yrs or the Inspection Interval
API 570 - Piping Thickness Readings Lesser of Life or maximum interval specified in
API 570 Table 6-1. (Max interval is either 5 or 10
yrs based on Piping Class)
External No relationship to Life. (Seems a bit weird, but
thats the way the Code is written)
API 653 - Tanks External Lesser of Life of Shell or 5 yrs
Internal Lesser of Full Life of Bottom or 20 yrs
UT of Shell Lesser of Life of Shell or 15 yrs

How do I determine the Next Inspection Date?

How do you determine when to change the oil in your car? The interval for an oil change is usually
3000 miles. So when is the next oil change due? Its the Last Oil Change plus the Interval.

For inspection schedules, the Next Inspection Date works exactly the same. When is an equipment
inspection due? Its just the Last Inspection Date plus the Interval. Here is the formula.

Formula #3: Next Inspection Date = Last Inspection Date + Interval

Next Inspect Date

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Illustration: Calculate the Next Inspection Date
Here is the data for a vessel. Determine the Interval and Next Inspection Date for the Internal Inspection.

Vessel Data
Vessel Remaining Life Last Inspection
V-100 12 yrs January 2004

Step 1 - Calculate the Interval

Interval = Lesser of life or 10 yrs (Per API 510 Code)
= Lesser of: 12 x = 6 yr, or 10 yrs
= 6 yrs

Step 2 - Calculate the Next Inspection Date (NID)

NID = Last Inspection Date + Interval
= January 2004 + 6 yrs
= January 2010

Exercise 8: Calculate the Next Inspection Date

Here is the data for a vessel. Determine the Interval and Next Inspection Date for the Internal Inspection.

Vessel Data
Vessel ID Remaining Life Last Inspection
V-200 14 yrs March 2003

Step 1 - Calculate the Internal Interval

Interval = Lesser of: __________________________________
= Lesser of: __________________________________
Remember!
=
Always write the formula!
Step 2 - Calculate the Next Inspection Date (NID)
NID =
=
=

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Illustration: Calculate the Next Inspection Date with Odd Months
Not all inspection intervals are in nice round years. Suppose a vessel has a Remaining Life of 9.5 yrs.
Then the Internal Inspection Interval is 4.75 yrs. Determining this Next Inspection Date is a bit more
difficult. Lets show you how its done. Here is the data for this vessel. Determine the Next Inspection
Date for the Internal Inspection.
Vessel Data

Vessel Remaining Life Last Inspection

V-300 9.5 yrs October 2003

Step 1 - Calculate the Interval

Interval = Lesser of life or 10 yrs (Per API 510 Code)
= Lesser of: 9.5 x = 4.75 yr, or 10 yrs
= 4.75 yrs

Step 2 - Convert the Last Inspection Date to a Number)

October 2003 = 2003-10/12 = 2003.83

Step 3 - Calculate Next Inspection Date (NID)

NID = Late Inspection Date + Interval
= 2003.83 + 4.75 yrs
= 2008.58

Step 4 - Convent the Partial Year to Months

Partial Year is 0.58 yr (there are 12 months in a year)
# of Months = 0.58 yr x 12 months/yr = 6.96 months = 7 months
The 7th month is July

Step 5 - The Final Answer

July 2008

Looking ahead to the

next Inspection.

To convert year & months

Partial Yr to Months: # of Months = Partial Year x 12
Months to Partial Yr: Partial Year = # of Months / 12

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 Exercise 9: Calculate the Next Inspection Date
Determine the Next Inspection Date for the Internal Inspection for each of the vessels in this Table. The
first row is completed as an example.

Last Insp Last Insp Remaining Inspection Next Insp Convert Next Insp
Date Date Life Interval Date Partial Yr Date
(number) (yrs) (yrs) (number) to Months
V-10 April 2001 2001.33 18.7 9.35 2010.68 8.16 Aug 2010
V-20 Feb. 2002 9
V-30 Sept 2003 5.5
V-40 Nov. 2001 20
V-50 May 2003 11.2

Short-Term vs. Long-Term Corrosion Rates

Most Codes suggest you calculate the Long-Term and Short-Term corrosion rates. The Short-Term
corrosion rate is based on metal lost between the last two reading thickness at a TML. The Long-Term
corrosion rate is based on metal lost between the first and last thickness readings at a TML.

Advantages: Since process conditions often change over the life of the equipment, the Short-Term
corrosion rate is usually a better indicator of the current conditions. But this corrosion rate is subject to
greater inaccuracy when there are inaccurate thickness readings. The Long-Term corrosion rate is less
affected by inaccurate thickness readings.

The Corrosion Rate used in Remaining Life calculations is usually the greater of the Long-Term and Short-
Term rates.

Formula #4: metal loss tprevious tlast

Short-Term Rate = =
Short-Term Rate time period time period

Formula #5: metal loss tfirst tlast

Long-Term Rate = =
Long-Term Rate time period time period

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Illustration: Short & Long-Term Corrosion Rates
For this TML, we have multiple thickness readings taken at different dates. Calculate the Short-Term and
Long-Term Corrosion Rates and the Remaining Life for the TML.

Thickness Data

tminimum Jan 2003 Jan 1998 Jan 1995 Jan 1993

0.380 0.440 0.465 0.480 0.500

Step 1 - Calculate Short-Term Corrosion Rate

tprevious tlast 465 440
ST Rate = = = 5 mpy
time period 5

Step 2 - Calculate Long-Term Corrosion Rate

tfirst tlast 500 440
LT Rate = = = 6 mpy
time period 10

Step 3 - Pick the Controlling Corrosion Rate (the highest)

Highest between: 5 & 6 mpy = 6 mpy

Step 4 - Calculate Remaining Life

This problem is worked in mils.
tlast tmin 440 380 If you work it in inches, the
Life = = = 10 yrs answer is the same!
Corrosion Rate 6

Which Corrosion Rate should you use?

Long-Term or Short-Term?
Select the larger rate!

What do we do with the Reading on January 1995?

For this TML, absolutely nothing!
Its not needed for either the short or long-term calculations.

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Exercise 10: Short & Long-Term Corrosion Rates
For this TML, we have multiple thickness readings taken at different dates. Calculate the Short-Term and
Long-Term Corrosion Rates and the Remaining Life for the TML. .

Thickness Data
tminimum Jun 2003 Jun 1997 Jun 1994 Jun 1990
0.640 0.718 0.742 0.745 0.750

Step 1 - Calculate Short-Term Corrosion Rate

ST Rate = = =

Step 2 - Calculate Long-Term Corrosion Rate

LT Rate = = =

Step 3 - Pick the Controlling Corrosion Rate (the highest)

Step 4 - Calculate Remaining Life

Life = = =

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Illustration: The Monster Calc
This calculation will be more detailed than anything you will have on the API exam. But this is real life!
For this vessel, calculate the Next Inspection Date for the Internal Inspection.

Thickness Data
tminimum May 2003 Oct 1998 May 1995 Jan 1991
0.395 0.454 0.477 0.492 0.500

Step 1 - Convert Dates to Numbers

May 2003 = 2003-5/12 = 2003.42

Oct 1998 = 1998-10/12 = 1998.83
Jan 1991 = 1991-1/12 = 1991.08

Step 2 - Calculate Short-Term Corrosion Rate

tprevious tlast 477 454 23
ST Rate = = = = 5 mpy
time period 2003.42 1998.83 4.59

Step 3 - Calculate Long-Term Corrosion Rate

tfirst tlast 500 454 46
LT Rate = = = = 3.7 mpy
time period 2003.42 1991.08 12.34

Step 4 - Pick the Controlling Corrosion Rate (the highest)

Highest between: 5 & 3.7 mpy = 5 mpy

Step 5 - Calculate Remaining Life

tlast tmin 454 395 59
Life = = = = 11.8 yrs
Corrosion Rate 5 5
Step 6 - Calculate Inspection Interval
Per API 510: Lesser of Life (0.5 x 11.8 = 5.9 yr) or 10 yrs = 5.9 yrs

Step 7 - Calculate the Next Inspection Date (NID)

NID = Last Insp Date + Interval
NID = 2003.42 + 5.9 = 2009.32

Step 8 - Convert Partial Year to Month

# of Months = 0.32 x 12 = 3.8 months, about 4th month (April)

Step 9 - Final Answer: April 2009

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Exercise 11: The Monster Calc
Heres a Monster Calc for you to do. The steps are listed as an aid. For this vessel, calculate the Next
Inspection Date for the Internal Inspection.

Thickness Data
tminimum Feb 2003 May 1997 Jun 1992 Nov 1985
0.212 0.288 0.296 0.305 0.322

Step 1 - Convert Dates to Numbers

Step 2 - Calculate Short-Term Corrosion Rate

Step 3 - Calculate Long-Term Corrosion Rate

Step 4 - Pick the Controlling Corrosion Rate (the highest)

Step 5 - Calculate Remaining Life

Step 6 - Calculate Inspection Interval

Step 7 - Calculate the Next Inspection Date (NID)

Step 8 - Convert Partial Year to Month

Step 9 - Final Answer:

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