ASME PCC-2 Repair Method Statement Generator

OpenAI API Key:

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Equipment Information

Equipment Type *

Component *

Material *

Design Press.

Oper. Press.

Design Temp.

Damage Information

Damage Type *

Damage Location

Damage Description *

t_actual (mm)

t_min (mm)

t_nominal (mm)

Inspection / NDE Data

Inspection Findings

Operating Conditions & Constraints

Operation Status

Fluid Service

Risk Level

Access

Time Constraint

Client / Special Requirement

Repair Method Statement

Fill in the equipment and damage information on the left panel,
then click Generate Repair Method Statement.

The system will query the Qdrant Vector DB and generate
a complete RMS using GPT-4o.

How the AI Uses Your Input

The system follows a RAG Pipeline: your inputs are converted into an embedding vector, which queries the Qdrant Vector Database (containing ASME PCC-2, API 510/570/571, API 579-1). The retrieved code sections + your inputs are then sent to GPT-4o to generate a professional Repair Method Statement.

Richer input → more precise code retrieval → better RMS.
The AI cannot guess what you don't tell it. Every field you fill in improves the output.

Field Impact Priority

Field	Impact on Output	Required?
Damage Description	Highest	CRITICAL
Damage Type	Very High	Required
t_actual / t_min / t_nominal	Very High	Required
Operation Status	High	Required
Material	High	Required
Inspection Findings	High	Optional
Fluid Service	Medium	Optional
Risk Level	Medium	Optional
Client Requirement	Medium	Optional

Common Mistakes to Avoid

❌ Leaving Damage Description blank or too short (e.g. just "corrosion found")
❌ Not entering t_actual, t_min, t_nominal — AI cannot evaluate FFS without these
❌ Selecting "Online" but not specifying fluid service — affects Hot Work / repair method selection
❌ No NDE method selected — affects NDE plan in the output
❌ Skipping Damage Location — affects access and repair scope

Equipment Type Required

Select the type of pressurized equipment. This drives which code section applies (API 510 for vessels, API 570 for piping, API 653 for tanks).

Selection	Governing Inspection Code	PCC-2 Applicability
Pressure Vessel	API 510 / ASME VIII	Full — all repair articles
Piping	API 570 / ASME B31.3	Full — especially composite/sleeve
Storage Tank	API 653 / API 570	Weld overlay, insert plate
Heat Exchanger	API 510 / TEMA	Weld buildup, plug repair
Boiler	ASME I / NB-23	Requires NBIC, not PCC-2 only

Component Required

Specifies the exact component. Critical for selecting repair article — a Shell repair differs from a Nozzle or Weld Seam repair. Be specific.

Shell = most standard weld/composite options.
Nozzle = often requires replacement or reinforcement pad.
Weld Seam = crack excavation + weld repair protocol.

Material Required CRITICAL for Welding

Enter the material specification including grade. This determines Preheat, PWHT requirements, weld consumable selection, and whether welding is feasible.

Good examples: SA-516 Gr.70 → Carbon steel, moderate temp vessel A106 Gr.B → Carbon steel pipe SA-240 Type 316L → Stainless steel vessel/tank A312 TP316L → Stainless pipe SA-387 Gr.11 Cl.2 → Cr-Mo alloy steel (high temp) Duplex 2205 (UNS S31803)→ Duplex stainless pipe

If you input only "Carbon Steel" or "Stainless Steel" without the grade, the AI cannot determine correct preheat temperature, PWHT requirements, or consumable specifications.

Design / Operating Pressure & Temperature Recommended

Provide both design and operating conditions. The AI uses this to evaluate remaining life, select pressure test value, and assess repair feasibility.

Design Pressure : 150 psig | Oper. Pressure : 120 psig Design Temp : 300°F | (include units: psig, barg, °F, °C)

Damage Type Required

Select the closest matching damage mechanism. This is the primary key used to query the vector database for the correct code sections.

Damage Type	API 571 Mechanism	Likely PCC-2 Repair
General Corrosion	Atmospheric / CUI	Weld buildup, composite sleeve
Localized Corrosion	Under-deposit, MIC	Weld patch, insert plate
Pitting Corrosion	Chloride pitting	Weld repair, composite
Erosion-Corrosion	Flow-accelerated corrosion	Weld buildup at ID
SCC	Stress corrosion cracking	Excavation + weld repair, PWHT
HIC / SOHIC	Hydrogen-induced cracking	Window cut + insert plate
Wall Thinning	General / erosion thinning	Sleeve, composite wrapping
Active Leak	Any through-wall	Leak clamp (online), weld offline

Damage Description MOST CRITICAL FIELD

This is the single most important input. Write a detailed technical narrative covering: location, size (L×W), depth, pattern, severity, extent, and any relevant history.

✅ GOOD — Detailed and specific:
"External localized corrosion found at bottom shell (6 o'clock position), approximately 200mm × 150mm area. UT scan shows minimum wall thickness 6.2mm at the deepest point. Surrounding area measures 8.5–9.0mm. Nominal thickness is 10mm. Corrosion pattern is irregular, associated with CUI under damaged insulation. No cracking observed."

❌ BAD — Too vague:
"Found corrosion on shell" — AI cannot determine size, depth, FFS status, or appropriate repair method.

Include: location → size (LxW mm) → depth/min thickness → pattern → any cracks → history/cause (if known)

Thickness Values (t_actual / t_min / t_nominal) CRITICAL

Value	Definition	Where to Get It
t_actual	Measured minimum remaining wall thickness	UT scan minimum reading
t_min	Minimum required thickness (by code or design calc)	Design calculation, data sheet, or API 579 Level 1
t_nominal	Original specified (nominal) thickness	Original design drawing / mill cert

If t_actual < t_min → Repair Required
If t_actual ≥ t_min → FFS acceptable, AI may recommend monitoring.

Example: t_nominal = 10.0 mm | t_actual = 6.2 mm | t_min = 5.5 mm → t_actual (6.2) > t_min (5.5): Currently acceptable but approaching limit → AI will recommend repair to restore safety margin

NDE Method Selection

Select ALL NDE methods that have been performed. Each method unlocks specific requirements in the RMS output.

Method	Best For	Drives in RMS Output
UT Scan	Wall thickness measurement, corrosion mapping	Baseline data, post-repair UT verification
RT	Weld quality, volumetric defects	RT of completed weld repair
PT	Surface-breaking cracks, weld surface	Inter-pass PT during weld repair
MT	Surface/near-surface cracks in ferrous	Pre/post-weld MT requirements
VT	Visual inspection, surface condition	Pre-repair VT, post-repair VT
PAUT	Advanced crack sizing, weld inspection	High-confidence NDE plan in RMS
TOFD	Through-wall crack sizing	Precise crack depth for repair scope

Inspection Findings Recommended

Summarize the key NDE findings. Be specific with numbers. This directly populates the "Current Condition Assessment" section of the RMS.

✅ GOOD example:
"UT grid scan (50mm × 50mm) performed over 300mm × 300mm area. Minimum UT reading: 6.2mm at 6 o'clock position. Average readings: 8.5–9.0mm. No lamination detected. MT on adjacent weld seam — no relevant indications. Corrosion rate estimated at 0.45mm/yr."

Include: minimum reading + location, scan grid size, comparison to previous readings, corrosion rate if calculated.

Operation Status Required

This is a major decision gate — it determines whether online repair methods (clamps, composites) or offline methods (welding, cutting) are applicable.

Status	Available Repair Methods	Welding Allowed?
Online (In-Service)	Mechanical clamp, leak box, composite wrapping, injection clamp	Hot tap only (special permit)
Offline (Shutdown)	All methods — weld repair, insert plate, sleeve, replacement	Yes — full welding allowed
Depressurized / Isolated	Most weld methods — depends on purge/gas free	Yes — after gas free verification

Fluid Service Recommended

Fluid Service	Key Constraints
Hydrocarbon Liquid/Gas	Hot work permit, LEL monitoring, purge before welding
Toxic / Lethal	Strict isolation, full PPE, no online hot work
Hydrogen Service	PWHT mandatory, HTHA risk, HIC check required
Caustic / Alkali	Caustic SCC risk — PWHT required after weld repair

Client / Special Requirement Optional but Valuable

Useful inputs: "Permanent repair required — temporary clamp not acceptable" "No hot work permitted while equipment is online" "PWHT required after any weld repair — per owner spec" "Composite repair must meet ISO 24817 / ASME PCC-2 Part 4" "Repair must last until next turnaround in 2027"

Example 1 — Wall Thinning on Pressure Vessel (Offline Weld Repair)

Equipment Type : Pressure Vessel Component : Shell Material : SA-516 Gr.70 Design Pressure : 150 psig | Oper. Pressure: 120 psig | Design Temp: 300°F Damage Type : Localized Corrosion Damage Location : External bottom shell, 6 o'clock, 800mm from bottom head seam Damage Desc : Localized CUI corrosion found during insulation removal. Affected area approx. 250mm × 180mm. UT min reading: 6.2mm. Nominal thickness 10mm. Surrounding area 9.2–9.5mm. No cracking observed. Pitting depth max 3.8mm from OD. t_actual: 6.2 mm | t_min: 5.5 mm | t_nominal: 10.0 mm NDE Methods : UT, MT, VT Inspection Findings: UT grid 50×50mm. Min: 6.2mm at center of affected area. MT on adjacent weld seam — no indication. CUI confirmed. Status : Offline (Shutdown) Fluid Service : Hydrocarbon Liquid Risk Level : Medium Client Req : Permanent repair only. PWHT not required if t < 19mm.

Example 2 — Active Leak on Piping (Online Mechanical Clamp)

Equipment Type : Piping Component : Pipe / Straight Material : A106 Gr.B (6" Sch 40) Design Pressure : 200 psig | Oper. Pressure: 180 psig | Design Temp: 250°F Damage Type : Active Leak Damage Location : 6" crude oil line, 3rd flange from pump P-101, at 3 o'clock Damage Desc : Pin-hole leak through-wall at weld toe of circumferential weld. Seeping crude oil, estimated flow rate < 0.5 ml/min. t_actual: 3.5 mm (at leak point) | t_min: 4.5 mm | t_nominal: 8.18 mm NDE Methods : UT, VT Status : Online (In-Service) Fluid Service : Hydrocarbon Liquid Risk Level : High Time Constraint : Urgent (<24h) Client Req : Online repair required. Permanent solution at next TA.

Example 3 — SCC on Stainless Steel Vessel

Equipment Type : Pressure Vessel Component : Nozzle Material : SA-240 Type 316L Design Pressure : 75 psig | Oper. Pressure: 60 psig | Design Temp: 150°F Damage Type : Stress Corrosion Cracking (SCC) Damage Location : N1 inlet nozzle weld (2" nozzle-to-shell), external surface Damage Desc : Chloride SCC detected at external weld toe of 2" nozzle-to-shell weld. PAUT confirms crack depth 4mm through 6mm wall (67% through). Crack length 45mm measured by TOFD. Linear orientation, parallel to weld. t_actual: 2.0 mm (remaining ligament) | t_min: 3.0 mm | t_nominal: 6.0 mm NDE Methods : PAUT, TOFD, PT Status : Offline (Shutdown) Fluid Service : Caustic / Alkali Risk Level : Critical Client Req : Full crack excavation required. 316L filler metal only. No PWHT on 316L (sensitization risk).

Input Guide — How to Get the Best Repair Method Statement