UltraPIPE 10 Users Guide

DECEMBER 2004

Berwanger, Inc.
609 West State Street
Media, PA 19063
Phone: (610) 891-6762 Fax: (610) 891-9169
e-mail: support@ultrapipe.com
http://www.ultrapipe.com
http://www.berwanger.com
Copyright Berwanger, Inc., 1986 - 2004

GE Inspection Technologies, LP
P. O. Box 350
50 Industrial Park Road
Lewistown, PA 17044
Phone (717) 242-0320 Fax (717) 242-2606
e-mail: GEInspectionTechnologies@ae.ge.com
http://www.geinspectiontechnologies.com
Copyright Krautkramer, Inc., 1987 - 2004

TRADEMARKS
UltraPIPE is a registered trademark of the Berwanger Corporation. Microsoft, Windows, Windows NT, Microsoft Word,
and Microsoft Excel are trademarks or registered trademarks of Microsoft Corporation. AutoCad is a trademark or
registered trademark of Autodesk Corporation. MicroStation is a trademark or registered trademark of Bentley Systems
Corporation. Crystal Reports is a trademark or registered trademark of Seagate Software Corporation. RISKWISE is a
trademark of TWI Ltd. All rights reserved worldwide.

Table of Contents
Part 1 - UltraPIPE Basics
CHAPTER 1 - Introduction
About UltraPIPE........................................................................................................................................ 1-1
About this Manual ..................................................................................................................................... 1-3
Conventions used in this Manual.............................................................................................................. 1-5
System Requirements .............................................................................................................................. 1-5

CHAPTER 2 - Installation of UltraPIPE

Install UltraPIPE........................................................................................................................................ 2-1
Modify/Repair UltraPIPE........................................................................................................................... 2-6
Remove UltraPIPE.................................................................................................................................... 2-6

CHAPTER 3 - Running UltraPIPE

System Requirements .............................................................................................................................. 3-1
Starting UltraPIPE..................................................................................................................................... 3-1
Password Protection................................................................................................................................. 3-3
Administrative Level .......................................................................................................... 3-5
Current Setting at Startup ......................................................................................................................... 3-6
UPIPESET.MDB................................................................................................................ 3-6
UPIPE.INI .......................................................................................................................... 3-6
Use of the Windows System Registry ...............................................................................3-7
Prompt for KBDEF.MDB Location ............................................................................................................ 3-7
General Navigation in UltraPIPE .............................................................................................................. 3-9
Using Access to Open UltraPIPE Databases .........................................................................................3-10
Exiting UltraPIPE ....................................................................................................................................3-10

Part 2 - Using UltraPIPE

CHAPTER 4 - Adjusting Your Session Settings
Setting Selection ....................................................................................................................................... 4-2
Changing a Session Setting .............................................................................................. 4-2
Adding a Session Setting .................................................................................................. 4-2
Deleting a Session Setting ................................................................................................ 4-3
System Constants..................................................................................................................................... 4-3
Paths......................................................................................................................................................... 4-8
ADO Databases ......................................................................................................................................4-11
Data Logger Setup..................................................................................................................................4-13
Data Logger I/O ......................................................................................................................................4-14
Analytical Settings - Standard.................................................................................................................4-15
Analytical Settings - Advanced ...............................................................................................................4-18
Analytical Settings - 0 C.A. .....................................................................................................................4-21
i

Analytical Settings - Structural T-Min......................................................................................................4-23

Analytical Settings - RBI .........................................................................................................................4-25
Report Configuration...............................................................................................................................4-26

CHAPTER 5 - Adding/Renaming/Deleting and Linking Eq/Circ IDs in your Master

List
Adding an Eq/Circ ID ................................................................................................................................ 5-2
Renaming an Existing Eq/Circ ID ............................................................................................................. 5-6
Deleting an Existing Eq/Circ ID...............................................................................................................5-11
Linking Eq/Circ IDs to a Common Group Name.....................................................................................5-14
Add a New Group Name .................................................................................................5-15
Add Members to a Group Name .....................................................................................5-16
Delete Members from a Group name..............................................................................5-17
Rename a Group.............................................................................................................5-18
View Groups ....................................................................................................................5-18
View Equipment ..............................................................................................................5-19

CHAPTER 6 - Corrosion Monitoring

Analysis Description Including Determining Corrosion Rates, Retirement Dates and
Recommended Inspection Due Dates ...................................................................................................... 6-2
TML T-Min and MAOP Calculations.................................................................................. 6-3
Representative TML Corrosion Rate................................................................................. 6-3
Temperature Correction .................................................................................................... 6-5
Growths ............................................................................................................................. 6-5
Representative Eq/Circ ID and Group Corrosion Rates (Advanced Option) .................... 6-6
TML Retirement Date ........................................................................................................ 6-6
Define TMLs as Zero Corrosion Allowance or Non-Zero Corrosion Allowance................ 6-7
TML Inspection Due Date for Non-Zero Corrosion Allowance TMLs................................ 6-7
TML Inspection Due Date for Zero Corrosion Allowance TMLs........................................ 6-8
Eq/Circ ID and Group Retirement Dates........................................................................... 6-8
Define Eq/Circ IDs as Zero Corrosion Allowance or Non-Zero Corrosion
Allowance .......................................................................................................................... 6-9
Eq/Circ ID and Group Inspection Due Dates for Non-Zero Corrosion Allowance
Eq/Circ IDs ........................................................................................................................ 6-9
Eq/Circ ID and Group Inspection Due Dates for Zero Corrosion Allowance Eq/Circ
IDs ...................................................................................................................................6-10
Caution TML Calculation .................................................................................................6-11
Adding/Modifying an Eq/Circ ID and TMLs.............................................................................................6-11
Adding an Eq/Circ ID and TMLs......................................................................................6-30
Editing an Eq/Circ ID and TML........................................................................................6-31
Deleting an Eq/Circ ID and TML .....................................................................................6-31
Adding/Modifying a Survey .....................................................................................................................6-32
Adding a Thickness Survey.............................................................................................6-37
ii

Adding a Thickness Reading to an Existing Survey .......................................................6-38

Editing a Thickness Survey .............................................................................................6-38
Deleting a Thickness Survey...........................................................................................6-39
Deleting a TML Reading from a Thickness Survey.........................................................6-40
View TML Thickness and Attachment Data............................................................................................6-40
Activate/Inactivate TMLs.........................................................................................................................6-41
Lock/Unlock Analysis Settings................................................................................................................6-42
Using Global Analysis Options ...............................................................................................................6-43
RBI Methodology with Corrosion Monitoring ..........................................................................................6-45

CHAPTER 7 - Component Codes

Component Codes for Piping.................................................................................................................... 7-2
Component Codes for Vessels ................................................................................................................. 7-8
Vessel Type 01 - Cylindrical Shell..................................................................................... 7-9
Vessel Type 02 - Spherical Shell ....................................................................................7-10
Vessel Type 03 - Ellipsoidal Head- Unstayed .................................................................7-11
Vessel Type 04 - Torispherical Head - Unstayed............................................................7-12
Vessel Type 05 - Hemispherical Head............................................................................7-13
Vessel Type 06 - Conical Head (without Transition Knuckle) .........................................7-13
Vessel Type 07 - Toriconical Head (Conical Portion) .....................................................7-14
Vessel Type 08 - Toriconical Head (Knuckle Portion) ....................................................7-15
Vessel Type 09 - Pipe Nozzles .......................................................................................7-15
Vessel Type 10 - Flat Head: Circular, Unstayed .............................................................7-16
Vessel Type 11 - Flat Head: Circular, Unstayed, Bolted with Edge Moment..................7-16
Component Codes for Tankage..............................................................................................................7-17
Tankage Type 01 - Roof Plate ........................................................................................7-18
Tankage Type 02 - Welded Shell, 1st and 2nd Course ..................................................7-19
Tankage Type 03 - Welded Shell, 3rd Course and Above..............................................7-19
Tankage Type 04 - Riveted Shell, All Courses ...............................................................7-20
Tankage Type 05 - Floor Plate........................................................................................7-21
Tankage Type 06 - Annular Ring ....................................................................................7-21
Tankage Type 07 - Nozzle ..............................................................................................7-22
Component Codes for Boilers.................................................................................................................7-22
Boiler Type 01 - Tubing ...................................................................................................7-23
Boiler Type 02 - Piping, Drums and Headers..................................................................7-24
Boiler Type 03 - Dished Head, Blank, Unstayed.............................................................7-24
Boiler Type 04 - Blank, Unstayed, Full Hemispherical....................................................7-25
Boiler Type 05 - Flat Head, Unstayed, Circular...............................................................7-25
Boiler Type 06 - Flat Head, Unstayed, Circular, Bolted with Edge Moment ...................7-26
Boiler Type 07 - Flat Head, Unstayed, Non-Circular.......................................................7-27

iii

CHAPTER 8 - Material Codes

Material Codes for Piping ......................................................................................................................... 8-1
Material Codes for Vessels....................................................................................................................... 8-3
Material Codes for Tankage ..................................................................................................................... 8-5
Material Codes for Boilers ........................................................................................................................ 8-7

CHAPTER 9 - T-Min and MAOP Calculations

Using the Piping T-Min Calculator ............................................................................................................ 9-3
Structural T-Min Field ........................................................................................................ 9-6
Pressure T-Min and MAOP Calculations .......................................................................... 9-7
Using the Pressure Vessel T-Min Calculator............................................................................................ 9-9
Structural T-Min Calculations ..........................................................................................9-11
Pressure T-Min and MAOP Calculations ........................................................................9-12
Using the Atmospheric Tankage T-Min Calculator .................................................................................9-17
Structural T-Min Calculations ..........................................................................................9-19
Pressure T-Min and Maximum Fill Height Calculations ..................................................9-20
Using the Power Boiler T-Min Calculator................................................................................................9-22
Structural T-Min Calculations ..........................................................................................9-24
Pressure T-Min and MAOP Calculations ........................................................................9-25

CHAPTER 10 - Localized Corrosion on Piping

Add data for a Localized Corrosion Point ...............................................................................................10-1
Modify Data for a Localized Corrosion Point ..........................................................................................10-5
Remove Data from a Localized Corrosion Location ...............................................................................10-5

CHAPTER 11 - Valve Testing

Adding/Modifying/Deleting Valve Information.........................................................................................11-1
Adding an Eq/Circ or Valve ID to the Valve Module .......................................................11-3
Editing or Modifying a Valve Entry ..................................................................................11-8
Deleting an Eq/Circ ID.....................................................................................................11-8
Adding/Modifying/Deleting Valve Associations.......................................................................................11-8
Adding an Association.....................................................................................................11-9
Modifying an Association...............................................................................................11-10
Deleting an Association ................................................................................................11-10
Adding/Modifying/Deleting Valve Testing Results ................................................................................11-10
Adding Valve Test Results ............................................................................................11-11
Modifying Valve Test Results ........................................................................................11-16
Removing Valve Test Results .......................................................................................11-16

CHAPTER 12 - Equip/Circ ID Drawings for AutoCAD or any Viewer

Adding/Editing/Deleting UltraPIPE Database AutoCAD Drawing Information .......................................12-2
Adding Database Information for an AutoCAD Drawing .................................................12-2
Editing Database Information for an AutoCAD Drawing .................................................12-5
iv

Deleting Database Information for an AutoCAD Drawing ...............................................12-7

Displaying an AutoCAD Drawing ............................................................................................................12-8
Incorporating an Existing AutoCAD Drawing in UltraPIPE .....................................................................12-9
Associating an Existing Drawing with an Eq/Circ ID .......................................................12-9
Inserting an Existing Drawing as a Block into a Prototype............................................12-11
Batch Update/Print for AutoCAD 2000 or Later....................................................................................12-12
Batch Update without Printing for AutoCAD 2000 or Later ...........................................12-12
Batch Update with Printing for AutoCAD 2000 or Later ................................................12-13
Assigning Page Setup Information and Drawing Markers to the Batch Update/Print ..........................12-18
Editing AutoCAD Drawing Marker Designs ..........................................................................................12-19
Drawing Prototypes for AutoCAD .........................................................................................................12-21
UltraPIPE Menu for AutoCAD...............................................................................................................12-21
Loading the UltraPIPE Pull-Down Menu .......................................................................12-21
Loading the UltraPIPE Side-Screen Menu....................................................................12-22
UltraPIPE Custom Menu Options..................................................................................12-23
UltraPIPE and PIPE+ Menus ........................................................................................12-23
EDIT DWG UltraPIPE Menu..........................................................................................12-23
EDIT DWG PIPE+ Menu ...............................................................................................12-25

CHAPTER 13 - Equip/Circ ID Drawings Using MicroStation

Adding/Editing/Deleting UltraPIPE Database MicroStation Drawing Information ..................................13-2
Adding Database Information for a MicroStation Drawing ..............................................13-3
Editing Database Information for a MicroStation Drawing...............................................13-5
Deleting Database Information for a MicroStation Drawing ............................................13-7
Displaying a MicroStation Drawing .........................................................................................................13-8
Editing MicroStation Drawing Marker Designs .......................................................................................13-9
UltraPIPE Palette for MicroStation........................................................................................................13-11
Converting Existing PIPE+ 5.0A and Earlier Drawings Using the MS Link System...........................13-12

CHAPTER 14 - Transferring Data between UltraPIPE and a Portable Data Logger

Sending Data to a KB Data Logger or StressTel T-Scope III .................................................................14-2
Sending Data to the DMS 2, DMS, or StressTel T-Scope III Using the Standard
DMS File Formats ...........................................................................................................14-2
Sending Data to the USN 60 ...........................................................................................14-6
Sending Data to the DR1 ................................................................................................14-9
Receiving Data from a KB Data Logger or StressTel T-Scope III ........................................................14-11
Receiving Data from the DMS, DMS 2, or StressTel T-Scope III .................................14-11
Receiving Data from the DR1........................................................................................14-16
Receiving Data from a DME DL, DM4 DL and USN 50/52 ...........................................14-17
Writing Data to DATAMATE, DMSMATE, UltraMATE, or GridWare....................................................14-19
Reading Data from DATAMATE, DMSMATE, UltraMATE, GUS DMS, or GridWare ..........................14-22
Reading DMSMATE Files .............................................................................................14-23
Reading DATAMATE Files............................................................................................14-23
v

Reading UltraMATE, GUS DMS, or GridWare Files .....................................................14-24

Send Data to Another Device ...............................................................................................................14-28
Receive Data from Another Device ......................................................................................................14-30

CHAPTER 15 - Inspection Activity Schedules and Reports

Inspection Activity Scheduling ................................................................................................................15-1
Creating a New Inspection Activity..................................................................................15-2
Modifying an Existing Inspection Activity ........................................................................15-5
Deleting an Existing Inspection Activity...........................................................................15-8
Renaming an Existing Inspection Activity .......................................................................15-9
Adding an Eq/Circ ID to an Inspection Activity..............................................................15-10
Modifying Eq/Circ ID Information for an Inspection Activity ..........................................15-13
Deleting an Eq/Circ ID from an Inspection Activity........................................................15-15
Creating a New Inspection Activity Checklist ................................................................15-16
Modifying an Existing Inspection Activity Checklist.......................................................15-17
Deleting an Existing Inspection Activity Checklist .........................................................15-18
Adding an Inspection Activity Report ....................................................................................................15-18
Add/Edit/Delete Inspection Activity, Recommendation, and Repair Reports .......................................15-24
View/ Print Inspection Activity Reports .................................................................................................15-33

CHAPTER 16 - Utilities
Database Append ...................................................................................................................................16-1
Table Append..........................................................................................................................................16-5
Convert Access 97 UltraPIPE MDB Files to Access XP/2003 MDB Files..............................................16-7
Create a New Data Database.................................................................................................................16-7
Reading Notes List..................................................................................................................................16-8
Compact Databases (Jet Databases Only) ............................................................................................16-9
Databases Integrity Check (Jet Databases Only)...................................................................................16-9
Convert Access 97 UltraPIPE MDB Files to Access XP/2003 MDB Files............................................16-10
Update LATEST_DATE Field in KBVTEST..........................................................................................16-11
Rename AutoCAD Drawing Layers ......................................................................................................16-12

CHAPTER 17 - Inspection Personnel

Add/Edit/Delete General Information for a User .....................................................................................17-1
Add or Edit General Information for a User ............................................................................................17-2
Delete General Information for a User....................................................................................................17-3
Add/Edit/Delete Certifications and UltraPIPE Qualifications ..................................................................17-3
How to Input Current Personnel into the Various UltraPIPE User ID Fields ..........................................17-5

CHAPTER 18 - UltraPIPE Fixed Format Text Reports

Status Reports ........................................................................................................................................18-1
Corrosion Monitoring Reports.................................................................................................................18-3
Corrosion Monitoring Group Reports ..............................................................................18-3
Standard Corrosion Monitoring Reports..........................................................................18-6
vi

Corrosion Monitoring Reports for PVCalc .....................................................................18-12

Valve Testing/Inspection Reports .........................................................................................................18-14
Localized Corrosion Monitoring Reports ..............................................................................................18-17
Inspection Activity Schedules Reports .................................................................................................18-18
Inspection Activity Recommendations and Repairs Reports................................................................18-21
View/Print Inspection Activity Recommendation Information........................................18-22
View/Print Inspection Activity Repair Information..........................................................18-23
Personnel Reports ................................................................................................................................18-25
Security Module Reports ......................................................................................................................18-26
Exception Summary Reports ................................................................................................................18-27
Exception Summary Report Options.............................................................................18-28
Exception Summary Report Information .......................................................................18-29

CHAPTER 19 - Color Graphics Reports

Color Graphics Reports ..........................................................................................................................19-1
TML Color Grid Reports..........................................................................................................................19-4
Boiler TML Color Grid Reports ...............................................................................................................19-5

CHAPTER 20 - Advanced Reporting

MS Word Builder.....................................................................................................................................20-1
Designing a New Report .................................................................................................20-2
Launching an Existing Report .......................................................................................20-11
Editing an Existing Report .............................................................................................20-13
Copying an Existing Report...........................................................................................20-22
Deleting an Existing Report...........................................................................................20-23
Import or Export Existing Reports .................................................................................20-24
Import an Existing MS Word Builder Report ...........................................................20-24
Export an Existing MS Word Builder Report ...........................................................20-25
Report Package ....................................................................................................................................20-26
Add/Edit/Delete a Report Package ...............................................................................20-27
Run a Report Package ..................................................................................................20-29
Ad-Hoc Reporting through Crystal Reports ..........................................................................................20-30

CHAPTER 21 - Piping Construction Module

Adding/Modifying an Eq/Circ ID to the Piping Construction Module - Pipe Data ...................................21-2
General Data Tab............................................................................................................21-2
Construction Data Tab ....................................................................................................21-7
Operation Data Tab.........................................................................................................21-8
Insulation/Coatings Data Tab ........................................................................................21-10
Env/Safety Data Tab .....................................................................................................21-12
Associated Equip Data Tab...........................................................................................21-16
Access Data Tab ...........................................................................................................21-17
Adding/Modifying an Eq/Circ ID to the Piping Construction Module - Spools Data .............................21-18
vii

Design Data Tab ...........................................................................................................21-18

Properties Data Tab ......................................................................................................21-20
Material Data Tab..........................................................................................................21-23
ANSI Flange Data Tab ..................................................................................................21-26
Adding/Modifying an Eq/Circ ID to the Piping Construction Module - Fittings Data.............................21-27
Design Data Tab ...........................................................................................................21-27
Properties Data Tab ......................................................................................................21-33
Material Data Tab..........................................................................................................21-36
ANSI Flange Data Tab ..................................................................................................21-39
Adding/Modifying an Eq/Circ ID to the Piping Construction Module - Welds Data ..............................21-40
Type/Method Data Tab..................................................................................................21-40
Preheat Data Tab ..........................................................................................................21-44
Heat Treatment Box Data Tab ......................................................................................21-47
WPS Information Data Tab ...........................................................................................21-49
General Data Tab..........................................................................................................21-50
Deleting an Eq/Circ ID from the Piping Construction Module...............................................................21-50

CHAPTER 22 - Tank Construction Module

Adding/Modifying an Eq/Circ ID to the Tank Construction Module - Tank Data ....................................22-3
General Data Tab............................................................................................................22-3
Construction Data Tab ....................................................................................................22-8
Operation Data Tab.......................................................................................................22-10
Env/Safety Data Tab .....................................................................................................22-12
Internals Data Tab.........................................................................................................22-16
Associated Equip Data Tab...........................................................................................22-18
Adding/Modifying an Eq/Circ ID to the Tank Construction Module - Roof Data...................................22-19
General Data Tab..........................................................................................................22-19
Seals Data Tab..............................................................................................................22-22
Fittings Data Tab ...........................................................................................................22-24
Nozzles Data Tab..........................................................................................................22-25
Access Data Tab ...........................................................................................................22-29
Insulation/Coatings Data Tab ........................................................................................22-30
Adding/Modifying an Eq/Circ ID to the Tank Construction Module - Shell Data ..................................22-32
General Data Tab..........................................................................................................22-32
Shell Courses Data Tab ................................................................................................22-34
Nozzles Data Tab..........................................................................................................22-36
Access Data Tab ...........................................................................................................22-40
Insulation/Coatings Data Tab ........................................................................................22-41
Adding/Modifying an Eq/Circ ID to the Tank Construction Module - Floor Data ..................................22-43
General Data Tab..........................................................................................................22-43
Nozzle Data Tab............................................................................................................22-46
viii

Water Box Data Tab......................................................................................................22-50

Sump Data Tab .............................................................................................................22-50
Access Data Tab ...........................................................................................................22-52
Deleting an Eq/Circ ID from the Tank Construction Module.................................................................22-52

CHAPTER 23 - Vessel Construction Module

Adding/Modifying an Eq/Circ ID to the Vessel Construction Module - Vessel Data...............................23-3
U-1A Data Tab ................................................................................................................23-3
General Data Tab............................................................................................................23-5
Env/Safety Data Tab .....................................................................................................23-10
Internals Data Tab.........................................................................................................23-13
Associated Equip Data Tab...........................................................................................23-15
Insulation/Coatings Data Tab ........................................................................................23-16
Access Data Tab ...........................................................................................................23-18
SS Insul/Coatings Data Tab ..........................................................................................23-19
TS Insul/Coatings Data Tab ..........................................................................................23-21
Adding/Modifying an Eq/Circ ID to the Vessel Construction Module - Design/Operation Data............23-23
Design Criteria Data Tab...............................................................................................23-23
Operation Data Tab.......................................................................................................23-26
Adding/Modifying an Eq/Circ ID to the Vessel Construction Module - Shells Data..............................23-28
Design Data Tab ...........................................................................................................23-28
Welding Data Tab..........................................................................................................23-30
Material Data Tab..........................................................................................................23-31
Linings Data Tab ...........................................................................................................23-35
Adding/Modifying an Eq/Circ ID to the Vessel Construction Module - Heads Data .............................23-38
Design Data Tab ...........................................................................................................23-38
Welding Data Tab..........................................................................................................23-41
Material Data Tab..........................................................................................................23-42
Linings Data Tab ...........................................................................................................23-45
Adding/Modifying an Eq/Circ ID to the Vessel Construction Module - Nozzle Data.............................23-48
Design Data Tab ...........................................................................................................23-48
ANSI Flange Data Tab ..................................................................................................23-51
Welding Data Tab..........................................................................................................23-52
Material Data Tab..........................................................................................................23-53
Linings Data Tab ...........................................................................................................23-56
Reinforcement Pad Data Tab........................................................................................23-59
Adding/Modifying an Eq/Circ ID to the Vessel Construction Module - Transitions Data ......................23-62
Design Data Tab ...........................................................................................................23-62
Welding Data Tab..........................................................................................................23-64
Material Data Tab..........................................................................................................23-65
Linings Data Tab ...........................................................................................................23-69
ix

Adding/Modifying an Eq/Circ ID to the Vessel Construction Module - Stiffening Rings Data ..............23-72
Design Data Tab ...........................................................................................................23-72
Welding Data Tab..........................................................................................................23-76
Material Data Tab..........................................................................................................23-77
Adding/Modifying an Eq/Circ ID to the Vessel Construction Module - Flanges Data...........................23-80
Design Data Tab ...........................................................................................................23-80
Bolting Data Tab............................................................................................................23-87
Welding Data Tab..........................................................................................................23-90
Material Data Tab..........................................................................................................23-91
Adding/Modifying an Eq/Circ ID to the Vessel Construction Module - Tubesheets/Bundles Data.......23-94
Tubesheets Data Tab....................................................................................................23-94
Tube Bundles Data Tab ..............................................................................................23-102
Expansion Joints Data Tab .........................................................................................23-109
Deleting an Eq/Circ ID from the Vessel Construction Module............................................................23-117

CHAPTER 24 - Slurry Piping Module

Slurry Piping Setup .................................................................................................................................24-1
Documenting and Analyzing Pipe Rotation/Pipe Flip Data ....................................................................24-4
Documenting Pipe Rotation/Pipe Flip Data.....................................................................24-4
Analyzing Pipe Rotation Data..........................................................................................24-5
Volumetric Throughput Data...................................................................................................................24-6
Volumetric Throughput Input Options .............................................................................24-6
Calculating Volumetric Corrosion Rates (VCRs) ..................................................................................24-11
Straight Line Analysis Methods .....................................................................................24-11
Representative TML Volumetric Corrosion Rate...........................................................24-11
Statistical Analysis Methods..........................................................................................24-11
Representative Eq/Circ ID Volumetric Corrosion Rate .................................................24-11
Overwriting TML Quantities for Replacement Spools...........................................................................24-11
Corrosion Monitoring Reports for Slurry Piping ....................................................................................24-13

CHAPTER 25 - RISKCalc Module

RBI Assessment Process .......................................................................................................................25-2
Inspection and Maintenance Planning....................................................................................................25-3
Starting the RISKCalc Module ................................................................................................................25-4
Create New Equipment Item...................................................................................................................25-4
Item Properties ................................................................................................................25-4
Damage Mechanisms......................................................................................................25-6
Inspection Methods .........................................................................................................25-6
Risk Factors.....................................................................................................................25-7
Likelihood Factors ...........................................................................................................25-8
LF1 Current Condition...............................................................................................25-8
LF2 Failure Likelihood...............................................................................................25-8
x

LF3 Inspection Effectiveness ....................................................................................25-9

LF4 Third Party Damage Potential............................................................................25-9
LF5 Ground Movement Potential ..............................................................................25-9
LF6 Operation in Relation to Design.......................................................................25-10
LF7 Recurring Repairs ............................................................................................25-10
Consequence Factors ...................................................................................................26-10
CF1 Product Loss ...................................................................................................25-10
CF2 Pressure Factor...............................................................................................25-11
CF3 Explosion/Fire Damage Potential....................................................................25-11
CF4 Toxicity ............................................................................................................25-12
CF5 Effect of Failure on Finances or Production ....................................................25-13
CF6 Location of Component Within Plant...............................................................25-13
CF7 Time Taken to Rectify Item Failure .................................................................25-13
CF8 Threat to Personnel and Environment ............................................................25-13
CF9 Engineered Safety Systems ............................................................................25-14
Risk Summary ...............................................................................................................25-14
Calculation of Risk ..................................................................................................25-14
Record Properties .........................................................................................................25-15
Written Scheme of Examination ....................................................................................25-16

CHAPTER 26 - Accessing UltraPIPE Help and Whats This Help

UltraPIPE Help........................................................................................................................................26-1
"What's This" Help ..................................................................................................................................26-1

Part 3 - Appendices
APPENDIX A - Sample Fixed Format Reports
Status Reports ..........................................................................................................................................A-3
Corrosion Monitoring Group Reports........................................................................................................A-4
Corrosion Monitoring Reports...................................................................................................................A-5
Valve Testing and Inspection Reports ......................................................................................................A-6
Localized Corrosion on Piping Report ......................................................................................................A-7
Inspection Activity Schedules ...................................................................................................................A-8
Inspection Activity Recommendations and Repairs .................................................................................A-9
Inspection Personnel Reports................................................................................................................ A-10

APPENDIX B - Sample Color Graphics Reports

APPENDIX C - Sample AutoCAD Drawings
APPENDIX D - Third Party Data Logger Communication Details
Parameters Passed to the Driver Program.............................................................................................. D-1
DataMate File Format for a Numeric Eq/Circ ID...................................................................................... D-2
DataMate File Format for a Grid Eq/Circ ID ............................................................................................ D-4
xi

Third Party Screen Access during Communications ............................................................................... D-6

Handling Communication Errors.............................................................................................................. D-6

APPENDIX E - Product Support

Installation and Hands-On Training ..........................................................................................................E-1
Installation and Hands-On Training(RISKCalc) ........................................................................................E-1
Support Contracts .....................................................................................................................................E-2
Custom Software Development ................................................................................................................E-2
UltraPIPE Gulf Coast Service Center .......................................................................................................E-3
Contacting Berwanger, Inc.. .....................................................................................................................E-3

APPENDIX F - SAP - UltraPIPE Interface

Current SAP - UltraPIPE Interface............................................................................................................F-1
Adding/Editing/Deleting SAP Data............................................................................................................F-1
Viewing SAP Data .............................................................................................................F-2
Adding a SAP ID ...............................................................................................................F-2
Modifying a SAP ID ...........................................................................................................F-2
Deleting SAP Data ............................................................................................................F-2
UltraPIPE Procedures to attach a SAP Equipment Number To A Group Name in the Master List .........F-3
SAP Required Modifications and Export File Format For The Current UltraPIPE Interface ....................F-5

APPENDIX G - UltraPIPE Database Maps

APPENDIX H - Utility Conversion Programs
Convert PIPE+ V4.5 or 5.0 Data Files ..................................................................................................... H-1
Convert All Tech Windows Data Files ..................................................................................................... H-3
Convert Piping Data ......................................................................................................... H-3
Convert Vessel Data ........................................................................................................ H-4
Convert PCMS DOS Data Files............................................................................................................... H-4
Convert Corrosion Monitoring Data.................................................................................. H-5
Convert Inspect2 Data.................................................................................................... H-10
Convert PSV Data .......................................................................................................... H-11
Clean-UP TML Numbering after Conversion ................................................................. H-11
Convert N-SPECT Data Files ................................................................................................................ H-12
Convert Corrosion Monitoring Data................................................................................ H-12
Convert Conduit Data Files.................................................................................................................... H-13
Import DOS PVMS V2.05 Data Files ..................................................................................................... H-13
Import Excel Worksheet Data ................................................................................................................ H-14
Export Data to MS Excel........................................................................................................................ H-15

APPENDIX I - Basic SQL Statements

APPENDIX J Application Guide for Boiler Inspection
Adding a Boiler Eq/Circ ID to the Corrosion Monitoring Application......................................................... J-1
Transferring Data between UltraPIPE and a Portable Data Logger......................................................... J-4

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Sending Data to the DMS 2, DMS, or StressTel T-Scope III Using the Standard
DMS File Formats ............................................................................................................. J-4
Sending Data to the DR1 .................................................................................................. J-4
Receiving Data from the DMS, DMS 2, or StressTel T-Scope III ..................................... J-5
Writing Data to DATAMATE, DMSMATE, UltraMATE, or GridWare ................................ J-5
Reading UltraMATE, GUS DMS, or GridWare files .......................................................... J-5
Boiler TML Color Grid Reports ................................................................................................................. J-5

APPENDIX K RBI Methodology in UltraPIPE

Step 1: Assign Matrix by Creating Inspection Activities............................................................................K-2
Functionality of RBI Methodology with Corrosion Monitoring...................................................................K-5
Step 2: Assign Eq/Circ IDs to the Inspection Activities.............................................................................K-8
Step 3: Perform Inspection and Document Results............................................................................... K-14
Create an Inspection Report .......................................................................................... K-14
Step 4: View/Print Inspection Reports ................................................................................................... K-20
Global Setup of RBI Activity Scheduling for Previously Scheduled Activities ....................................... K-20

APPENDIX L Configuring UltraPIPE for Microsoft SQL Server 2000

Installing Microsoft SQL Server 2000 Client Components ....................................................................... L-1
Configure SQL Server 2000 ..................................................................................................................... L-5
Use of MSDE vs. Microsoft SQL Server 2000.......................................................................................... L-5
Considerations for Microsoft SQL Server Database Usage in UltraPIPE ................................................ L-8
System Constants ............................................................................................................. L-8
Database Append............................................................................................................L-10
Table Append ..................................................................................................................L-11

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