Overview of Corrosion Control Documents (CCDs)

This article provides a summary of the 2019 API Inspection & MI Summit keynote address, which offers a past, present, and future outlook on fixed equipment mechanical integrity from an industry professional with 50+ years of experience.

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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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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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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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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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If you are developing a mechanical integrity program, or you would like to optimize your existing mechanical integrity program, do you have qualified MI consultants to meet your regulatory needs? If you already have a sound, defensible MI inspection system in place, do you have qualified and experienced personnel maintaining your program?

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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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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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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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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.

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This publication outlines 101 Essential Elements that need to be in place and functioning well in order to effectively and efficiently preserve and protect the reliability and integrity of pressure equipment (i.e. vessels, exchangers, furnaces, boilers, piping, tanks, and relief systems) in the refining and petrochemical industry.

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