Corrosion Control Documents

API RECOMMENDED PRACTICE 970 FIRST EDITION, DECEMBER 2017

Special Notes

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Copyright © 2017 American Petroleum Institute

Contents

Page

1. Scope 1

2. Normative References 3

3. Terms, Definitions, and Acronyms 3

4. Introduction to Corrosion Control Documents/Systems 6

   1. Characteristics 6

   2. Key Components of a CCD 6

   3. Target Audience 7

   4. Inspection Program 7

   5. Process Unit Integrity 8

5. CCD Work Process 8

   1. General 8

   2. Premises and Assumptions Concerning the CCD Work Process 9

   3. CCD Team Members 10

   4. Roles, Responsibilities, and Accountabilities for the CCD Work Process 12

   5. Data Needed for the Team Meetings 13

   6. Unit Specific Corrosion Systems/Circuits 14

   7. Damage Mechanisms 16

   8. Desired Run Time 17

   9. Process Variables and IOWs 17

   10. Integration with Existing PSM and Operational Programs 18

   11. Updating the CCD 19

6. Implementation 20

7. Integrating CCDs with Other Related Work Processes 21

   1. CCDs as Part of New Construction or Revamp Project Deliverables 22

8. Document Maintenance and Revalidation 22

   1. Updating CCDs 22

   2. Finalizing the Updated CCD and CMDs 23

Annex A (informative) Example CCD Development and Implementation Process 24

Annex B (informative) Corrosion and Materials Damage Mechanisms Checklist 27

Annex C (informative) Training Course Contents 30

Annex D (informative) Typical Systems for Selected Processes 32

Annex E (informative) Example of a Simplified Corrosion Control Document 39

Annex F (informative) CCDs as Part of New Construction and Revamp Project Deliverables 48

Bibliography 50

Figures

1 Work Process Map: CCD Development, Review, and Update 10

Tables

1. CCD Documentation Responsibilities 11

2. Suggested Information to be Reported for Corrosion Systems 15

3. Suggested Information to be Reported for Corrosion Circuits 16

   v

   Contents

   Page

4. Personnel Group Training 21

1. Example CCD Development and Implementation Process 24

2. CCD Implementation Checklist 25

1. Corrosion and Materials Damage Mechanisms Checklist 27

2. Mechanical and Other Damage Mechanisms Checklist 29

1. Suggested Training Schedule 31

2. Suggested CCD Training Styles 31

1. Corrosion System #125 Example Equipment and Materials 40

2. Corrosion System #125 Example Injection and Mix Points 40

3. Corrosion System #125 Example Inspection History 41

4. Corrosion System #125 Example Active/Potential Damage Mechanisms 41

5. Corrosion System #125 Example Operating Envelope Limits 42

6. Corrosion System #125 Example Special Inspection Considerations—Equipment and Piping

   (in addition to API 570) 42

7. Corrosion System #125 Example Critcal Check Valves 42

8. Corrosion System #125 Example Critical Bundles 42

9. Corrosion System #125 Example Critical Thermowells 42

10. System 3 Example Injection and Mix Points and Dead Legs 44

11. Example 3 System Integrity Operating Windows 44

12. Example System 3 Equipment and Material Parameters 45

13. Active/Potential Equipment Degredation Mechanism Characteristics 47

vi

Corrosion Control Documents

1 Scope

This recommended practice (RP) provides users with the basic elements for developing, implementing, and maintaining a Corrosion Control Document for refining, and at the owner's discretion, may be applied at petrochemical and chemical process facilities.

A Corrosion Control Document (CCD) is a document or other repository or system that contains all the necessary information required to understand materials damage susceptibility issues in a specific type of operating process unit at a plant site. CCDs are a valuable addition to an effective Mechanical Integrity Program. They help to identify the damage mechanism susceptibilities of pressure-containing piping and equipment, factors that influence damage mechanism susceptibilities, and recommended actions to mitigate the risk of loss of containment or unplanned outages.

This recommended practice serves as the basis for tracking CCD development, implementation, and maintenance to maintain consistency and to integrate the CCD work process with other plant integrity programs, such as Management of Change (MOC), Process Hazards Analysis (PHA), and Reliability Centered Maintenance (RCM). Some of these programs have significant overlap with the development of CCDs, including Risk-based Inspection studies (see API RP 580 and RP 581), Integrity Operating Windows (see API RP 584), in-house unit corrosion reviews, circuitization/systemization programs, and similar types of corrosion studies. Development of CCDs can serve as a useful starting point for establishing these programs if they have not been undertaken.

This document provides the owner/user with information and guidance on the work processes for development and implementation of CCDs for the owners’/users’ process units. While some generic examples are provided in the text and in 5.9, this document does not contain a complete list of unit-specific CCDs or operating plant variables for the numerous types of hydrocarbon processing units in the industry.

The rigor of review, the level of documentation, and even the need to develop a CCD will depend on the complexity of the process unit under consideration and the inherent risk associated with the process. It is the responsibility of the facility owner/user to determine the level of detail contained within their CCD.

The scope of this standard includes:

• descriptions of CCDs and definitions of related terminology;

  
  

• creating, establishing, and maintaining CCDs;

  
  

• data and information typically needed to create CCDs;

  
  

• descriptions of the various types of CCDs needed for process units;

  
  

• documenting and implementing CCDs;

  
  

• reviewing, changing and updating CCDs;

  
  

• integrating CCDs with other risk management practices;

  
  

• roles and responsibilities in the CCD work process; and

  
  

• knowledge transfer to all stakeholders.

  
  

  
  

  1

  2 API RECOMMENDED PRACTICE 970

  
  

  
  

  Typical CCDs cover the pressure-containing components of fixed equipment. The types of equipment and associated components typically covered by CCDs are:

  
  

• pressure vessels,

  
  

• process piping,

  
  

• storage tanks atmospheric and pressurized,

  
  

• process heaters pressurized components, and

  
  

• heat exchangers.

  
  

  The following equipment is not typically covered by CCDs, but may be at the user’s option:

  
  

• instrument and control systems,

  
  

• pressure relief devices,

  
  

• pressure vessel internals,

  
  

• machinery components,

  
  

• pump casings and valve bodies,

  
  

• stacks/flues,

  
  

• electrical systems, and

  
  

• structural systems.

However, these systems and components may be covered by other types of Risk-based Inspection (RBI) or risk assessment work processes, such as RCM.

This recommended practice outlines the essential elements in defining, monitoring, and maintaining CCDs as a vital component of corrosion management (damage mechanism control strategies) and inspection planning, including RBI.

This RP does not address process operating windows established for normal process control, for the purposes of maintaining product quality, or for other operating factors unrelated to control for the purpose of maintaining equipment integrity and reliability. However, the contents of a comprehensive, good quality CCD can be the basis for establishing Integrity Operating Windows (IOWs) in accordance with API RP 584.

This RP is a guideline document for organizing Corrosion Control Documents. The owner/user of this RP may also develop internal documents that detail how their company will create and implement the processes suggested herein. Section 5 contains key points for establishing a site procedure that documents the CCD work process.

NOTE Even though CCDs are labeled “Documents” for the purposes of this RP, it is recognized that much of the suggested content of a CCD may, in fact, reside in separate folders and electronic information storage sites. These separate folders and electronic information storage sites may be considered suitable alternatives to creating a separate or standalone CCD. It is not the intention of this RP to require operators to create a new document, but instead to have the components discussed in this document available for use in a work process covering integrity management.