?This project addresses the pragmatic application of the new DOT/PHMSA MegaRule RIN 1 – 192.712 for recommended toughness values for determining if an ILI-detected axial flaw needs repair or can instead be observed for any future growth. The MegaRule toughness is expressed as the Charpy energy value, which came from Charpy test data at 50°F. However, the fracture toughness of a surface-cracked pipe is quite different than Charpy impact toughness values, es pecially if the Charpy data is in the brittle-to-ductile transition region. The surface-cracked pipe burst-pressure transition temperature can be considerably lower than the Charpy impact speci men transition temperature due to loading rates and constraint effects (bending versus tension loading). In cases with axial surface cracks in vintage base-metal pipe tests, the surface-cracked pipe burst pressure transition temperature was >200°F lower than the Charpy transition tempera ture. The procedures were extended to welds, and databases from member companies were ex amined to establish what Charpy energy values should be used to reflect the toughness of a sur face crack in the pipe at the operating temperatures and still be consistent with the MegaRule Charpy information and safety desires. As a result of this work, the following three Material Categories were identified. · Material Category 1 – All vintage base metal [these always had ductile initiation at nor mal minimum design operating temperatures, i.e., 50°F (10°C) and even 23°F (-5°C)]. · Material Category 2 – Most welds and HAZ (these also had ductile initiation at normal design minimum operating conditions, but some of the welds required passing a screen ing criterion to ensure they did not fall into Category 3). · Material Category 3 – Some vintage ERW-EFW and some vintage DSAW where they might fracture without any ductile tearing. Additionally, for each Material Category, there are three levels of analysis. · Level 1 is the simplest and provides guidelines if Charpy or toughness test data on the pipe line materials is not known. This level has greater conservatism than other levels where data exists due to comparatively higher uncertainty. · Level 2 is when the operator has Charpy data for the materials in their line. The Charpy data may only be at one temperature and may include different-sized Charpy specimens. Analysis of this data is needed to determine if there will be ductile initiation (i.e., the Charpy plateau energy is then used) rather than directly using the Charpy energy at the test temperature. · Level 3 is when the operator has more detailed fracture mechanics test data to pursue a more detailed fracture analysis for burst pressure predictions. This report presents the Level 1 procedure for each of the Material Categories, with a summary of some of the technical basis for how the Level 1 criterion was established. The Level 2 and 3 analyses are not presented in this report, other than some of the same information needed to sub stantiate the technical basis for the Level 1 values. There is a separate Level 2 and 3 report. Pragmatic Application of MegaRule RIN 1 – 192.712 Toughness Values ?