QCorroFFS-III: A quick ABAQUS plug-in for fitness-for-service assessment of corroded pipes based on API 579-1/ASME FFS-1

• QCorroFFS-III: A plug-in for fitness for service Level 3 assessment of pipes. • Handles pipe geometry, corrosion mapping, and meshing automatically. • Uses Mapped Field for precise corrosion modeling in shell elements. • Speeds up Level 3 fitness for service assessment and lowers cost. Pipeline integrity management is critical to ensuring the safe, reliable, and cost-effective operation of industrial systems. Operating under high pressures and in corrosive environments, pipelines are highly susceptible to mechanical damage and corrosion. Inadequate fitness-for-service (FFS) assessments and irregular inspections can result in severe consequences, including system failures, costly repairs, unplanned shutdowns, and even the replacement of critical assets. To address these challenges, this study introduces an innovative plug-in named QCorroFFS-III, developed for Level 3 FFS assessments of corroded pipelines using the Remaining Strength Factor (RSF) approach. The plug-in features advanced capabilities, including automated pipeline geometry generation, material selection based on the limit load method, implementation of corrosion maps using the Mapped Field technique, application of internal, external, and thrust pressures, as well as automated meshing. By streamlining complex analytical procedures, this tool significantly reduces the time and cost associated with FFS evaluations while enhancing technical accuracy. This article elaborates on the theoretical foundations underlying the design of the QCorroFFS-III plug-in and demonstrates its performance and effectiveness through several practical examples. The plug-in enables engineers to proactively and efficiently manage the pipeline lifecycle, ensuring production sustainability and economically safeguarding physical assets.