Integripedia Topic
Corrosion Control Documents (CCDs)
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:
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A description of the unit
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Any operating conditions, such as shutdown or startup, that may affect certain damage mechanisms
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Process flow and corrosion loop diagrams
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A list of probable damage mechanisms and failure modes, along with information on each
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Recommended inspection practices
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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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Related Topics
- Cathodic Protection
- Coatings
- Condition Monitoring Locations (CMLs)
- Damage Mechanisms
- Flue Gas Dew Point Corrosion
- Green Rot
- Pitting Corrosion
- Positive Material Identification (PMI)
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January/February 2021 Inspectioneering JournalBy John Reynolds at Intertek
If I suddenly accepted the position of site manager at your operating site, one of the first things I would do is trot on down to the FEMI group and ask questions to assess what we need to be doing to avoid the potential for big FEMI events.
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May/June 2019 Inspectioneering JournalBy Jarrod White at Pinnacle, and Kate Williamson at Pinnacle
CCDs are critical components of a well-maintained MI program and encompass all necessary and relevant MI information for a given process unit. This article defines the value of having CCDs and addresses how to effectively develop and implement them.
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January/February 2019 Inspectioneering JournalBy John Reynolds at Intertek
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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September/October 2018 Inspectioneering JournalBy Richard B. Eckert at DNV GL, 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...
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September/October 2018 Inspectioneering JournalBy Stephen P. Webb, P.E. 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...
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November/December 2015 Inspectioneering JournalBy 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...
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September/October 2014 Inspectioneering JournalBy 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...
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BlogJuly 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, & maintain adequate management systems to avoid failures. Nearly all failures that have occurred...
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BlogJuly 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 JournalBy 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...
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The Role of Corrosion Control in Achieving Excellence in Pressure Equipment Integrity and ReliabilityMay/June 2010 Inspectioneering JournalBy 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...
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