CONCEPT DEMONSTRATION
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V-1077 — Sour Water Drum V-1077

Alkylation Unit · Sour Water service · Installed Sep 1, 1987 (39 yrs in service)

Medium
Current Min. Thickness
0.940 in
t-min 0.857 in
Measured Corrosion Rate
1.05 mpy
ML-predicted: 1.65 mpy
Remaining Life
60+ yrs
Next Inspection Due
Aug 19, 2036
Interval: 10.0 yrs (API 510)

UT Thickness Trend

Minimum CML reading per inspection vs. ASME Sec. VIII t-min

Vessel Specification

MaterialSA-387-11 Cl.2 (1.25Cr-0.5Mo)
Design CodeASME BPVC Section VIII, Div. 1
Joint Efficiency0.85
Design Pressure480 psig
Design Temperature385 °F
Operating Pressure325 psig
Operating Temperature233 °F
Diameter53 in
Nominal Thickness0.999 in
Corrosion Allowance0.0938 in
H2S / Chloride421 / 83 ppm
Flow Velocity1.5 ft/s
Process pH7.94
InsulatedYes

Corrosion & Remaining-Life What-If

Adjust operating conditions to see the live model-predicted corrosion rate and implied remaining life

Live Prediction — What-If Model
0.10 mpy
Predicted corrosion rate under these conditions (-0.95 mpy vs. current measured rate)
Implied Remaining Life
60+ yrs
Implied Reinspection Interval
10.0 yrs

What-if model: standardized Ridge regression, R² 0.56 on held-out fleet data (3.25 mpy MAE). Runs entirely client-side for instant feedback — see Model Insights for the full fleet-scale ensemble model used for official predictions.

Governing Damage Mechanism — Wet H2S Damage (SSC/HIC)

API 571 §4.5.1

Hydrogen-induced cracking (HIC) and sulfide stress cracking (SSC) in carbon/low-alloy steel exposed to wet H2S service. Not detectable by thickness monitoring alone.

Recommended inspection approach: Wet fluorescent magnetic particle (WFMT) and UT shear-wave/AUBT surveys in addition to routine UT thickness, per API RP 571 and NACE SP0296.

This mechanism is crack-dominant — thickness monitoring alone will not detect it. See Standards & Documentation for the full NDE requirement.

Inspection History

UT thickness readings, most recent first

DateMethodCML CountAvg ThicknessMin CML Thickness
Aug 22, 2026UT Spot80.9581 in0.9401 in
Mar 10, 2025UT Grid (API 572)80.9597 in0.9427 in
Nov 28, 2022UT Spot80.9610 in0.9482 in
Jan 4, 2020UT Spot80.9646 in0.9573 in
Dec 11, 2016UT Grid (API 572)80.9676 in0.9482 in
Nov 7, 2013UT Spot80.9703 in0.9594 in
Apr 13, 2012UT Grid (API 572)80.9726 in0.9583 in
Dec 20, 2009UT Grid (API 572)80.9750 in0.9575 in
Jul 23, 2008UT Grid (API 572)80.9782 in0.9760 in
Dec 4, 2005UT Grid + RT80.9789 in0.9718 in
Jan 21, 2003UT Grid (API 572)80.9803 in0.9604 in
Apr 22, 2000UT Grid + RT80.9843 in0.9785 in
May 17, 1997UT Grid (API 572)80.9917 in0.9885 in
Jul 5, 1994UT Spot80.9905 in0.9868 in
Dec 13, 1991UT Grid (API 572)80.9945 in0.9776 in
Mar 29, 1990UT Spot80.9949 in0.9918 in