Last update: Jan 13, 2017
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.
Recommend changes or revisions to this definition.
November/December 2015 Inspectioneering Journal
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September/October 2014 Inspectioneering Journal
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.).
December 30, 2013 By Marc McConnell, P.E. at Versa Integrity Group
On November 19, 2013, API issued project/document number 970 for an entirely new Recommended Practice (RP). The scope of this project will be to develop a work process and a standardized approach to the development of Corrosion Control Documents (CCDs) that will apply to the most common refinery process units.
July 15, 2013 By John Reynolds at Intertek
This week’s post takes up right where last week’s post left off in our discussion on Corrosion Management and Control (CM&C) Management Systems. As I have said previously, this information is based off a series of articles I did on PEI&R MS, which you can reference here. Here are the last two Corrosion Management and Control Management Systems.
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.
September/October 2012 Inspectioneering Journal
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.
May/June 2010 Inspectioneering Journal
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.