A Corrosion Control Document (CCD), sometimes also known as a corrosion report, corrosion manual, or critical process variable, is a document responsible for summarizing a unit's process description and its corrosion circuits. This includes the damage mechanism in each circuit, as well as startup and shutdown corrosion influences. CCDs are an essential part of any risk-based inspection plan, allowing facilities to keep track of every element of operation, and allowing top efficiency and minimal shutdown times.
While the document is called a “corrosion” control document, it can cover mechanisms aside from just corrosion. Mechanisms such as fatigue cracking, hydrogen and temper embrittlement, and brittle fracture are covered as well. These documents are incredibly useful because they are able to provide an understanding for how to spot and avoid these mechanisms and how the mechanisms could afflict fixed equipment in service should they appear. This can help users avoid unexpected deterioration or damage of equipment and materials.
A proper CCD will usually include at least the following information:
A description of the unit
Any operating conditions, such as shutdown or startup, that may affect certain damage mechanisms
Process flow and corrosion loop diagrams
A list of probable damage mechanisms and failure modes, along with information on each
Recommended inspection practices
applicable integrity operating windows (IOW’s)
In a way, CCDs are similar to API RP 571, which provides an in-depth look at over 60 different damage mechanisms that can occur to process equipment in refineries. This is nearly every damage mechanism known to the refining and petrochemical manufacturing industries. A CCD on the other hand will cover a small fraction of those mechanisms (those which apply to the equipment the document covers), but will cover those mechanisms in much greater detail, and in ways that apply specifically to the piece of equipment being covered.
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September/October 2018 Inspectioneering Journal
By Rick Eckert at DNV GL - North America Oil & Gas, and Gerry Koch at DNV GL
Corrosion control knowledge and resources can be applied more effectively through the development and implementation of a corrosion management system (CMS). A CMS better-connects management system elements to the process of managing corrosion threats, thereby increasing ROI. |
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September/October 2018 Inspectioneering Journal
By Stephen P. Webb at Metegrity
Whether implementing a comprehensive AIM strategy for the first time or looking for ways to create overlap between AIM activities and documents that historically have acted as information silos, consider utilizing CCDs. They serve as a useful initiation point for centralizing all known material selection, degradation, process plant circuitization, known risks, recommendations, and inspection best practices. |
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November/December 2015 Inspectioneering Journal
By John Reynolds at Intertek
Once upon a time in the land of Ooze, there were two processing plants that boiled oil to make fuels and various other valuable petrochemical products. On one side of the river, rests a site called Perfecto Process Plant, while just across the river lies another plant called InZayna Zylum. |
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September/October 2014 Inspectioneering Journal
By John Reynolds at Intertek
Based on my 45+ years of experience working with fixed equipment mechanical integrity (FEMI) issues in the refining and petrochemical processing industry, this article summarizes what I believe are the top 10 reasons why pressure vessels and piping systems continue to fail, thus causing significant process safety events (e.g. explosions, fires, toxic releases, environmental damage, etc.). |
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Blog
July 28, 2014 By John Reynolds at Intertek
Fixed equipment mechanical integrity (FEMI) failures are not caused by damage mechanisms; rather, they're caused due to failure to create, implement, and maintain adequate management systems to avoid failures. Nearly all failures that have occurred in our industry could have been avoided if these human systems were more robust and sustainable in providing the primary layers of protection for FEMI. |
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Blog
July 1, 2013 By John Reynolds at Intertek
I will emphasize the systems, work processes and procedures for identifying and controlling the rate and types of deterioration in pressure equipment. These are not in any particular order, as they are meant to operate interdependently. |
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September/October 2012 Inspectioneering Journal
By John Reynolds at Intertek
Perhaps the most important work process to achieve success in fixed equipment PEI&R is to create Corrosion Control Documents (CCD’s) for each process unit. In this article, I expand upon that work process in order to guide the interested owner-user in creating CCD’s for their process units. |
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May/June 2010 Inspectioneering Journal
By John Reynolds at Intertek
Clearly, corrosion prevention and control has a major role in achieving excellence in Pressure Equipment Integrity and Reliability (PEI&R). But there is a lot more to PEI&R than just corrosion control. This article will show how corrosion control has a central role in PEI&R, but will also show how the management system (MS) for corrosion control must be integrated with 9 other important management systems shown in figure 1 in order to achieve excellence in PEI&R. |
