Damage Mechanism Review / Corrosion Study

The experts at Asset Optimization Consultants rely on their metallurgical consulting expertise specific to the refining, chemical, or pipeline processes to perform corrosion studies. The facilitation and alignment of knowledge from all participants in your company who are familiar with your process and operating equipment reveal valuable information about your asset. With the information we gather from the corrosion study, we determine proper inspection methods and process alignment.
Damage Mechanism Review and Corrosion Study

The experts at Asset Optimization Consultants review damage mechanisms and perform corrosion studies by utilizing their metallurgical consulting expertise specific to the refining, chemical or pipeline processes. With the information we gather, our consultants can determine a proper method of inspection and process alignment.

What is a Corrosion Study and Review?

A corrosion study can provide key inputs for the RBI program including potential damage mechanisms, corrosion types, and corrosion rates that allow criticality to be calculated. A corrosion study also provides information such as predictable or potential locations, flow considerations, fouling issues, etc. that help develop effective inspection plans. The corrosion study goes beyond reviewing internal metal loss and includes environmental cracking and other damage mechanisms that can affect the probability of failure (POF) of an asset even without experiencing metal loss (e.g. brittle fracture, high-temperature hydrogen attack – HTHA, creep). The corrosion study is also an opportunity for all parties, including the RBI implementation team, corrosion consultant, and plant personnel including inspectors, operations and process engineers to bring as much knowledge about the process unit to corrosion study process. Why? Because none of us is as smart as all of us. Ken Blanchard – author of The One Minute Manager

AOC offers three levels of corrosion studies:

Level 1 Corrosion Study

This high-level study is performed on simplified process flow diagrams (PFDs) and provides the simplest and quickest corrosion review of a unit, units, or a list of equipment and piping circuits.

Level 2 Corrosion Study

A Level 2 study is typically used to support an RBMI implementation project. It is also performed on simplified PFDs and based on the same requirements and work scope of Level 1 Corrosion Study with one addition: A summary report is provided to establish the basis on which the corrosion rates, environmental cracking, and other damage mechanisms were determined. The report also documents key findings and recommendations.

Level 3 Corrosion Study

This study level provides more detailed and in-depth analysis than a Level 2 Corrosion Study, but the details and extent of the study should be agreed upon with the client. It is also performed on simplified PFDs and is based on the same requirements and work scope as a Level 2 Corrosion Study, but it usually leads to a Corrosion Control Manual.


We understand that you have a vision for achieving your future MI goals globally, which includes achieving meaningful, measured and early time to value. But quite often, companies are looking for the big ticket item, like cost savings from not inspecting lower risk assets or reducing the number of required internal inspections. They lose sight of the fact that a really significant finding is when we discover cracks in a series of heat exchangers housing ethylene oxide prior to completing a turnaround that, if left unrepaired or not replaced, could result in a catastrophic event.

AOC can prove that the risk of certain pressure vessels remains low over multiple turnaround periods, thanks to corrosion studies as part of an RBI project. In other words, we can avoid a bet-your-company event.

The question you should ask yourself is, "Would we have done a corrosion study anyway if we did not commit to the RBI project?" Maybe you would have. But there are so many inherent benefits from executing projects like risk based inspection. From organizing files to reduce downtime from an unplanned shutdown to training your people and updating work processes and procedures, RBI allows you to build a culture committed to safety. It is not just mechanical integrity that results from these programs but organizational integrity.

In addition to the human factor, we want to talk with you about how to get your best practice rolled out across the global enterprise - with sustainability and improvement.

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Mechanical Integrity and Reliability: From Anticipating Failure Modes to Planning

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Development of a Risk-Based Inspection Implementation Manual

The Materials Institute has developed a manual for implementing risk based inspection programs throughout the process industries.

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Common sense instructions on RBI value, implementation, design, and maintenance.

Instrument Reliability Manual

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The Integration of Risk-Based Inspection with Real Time Process Data

Even before IOWs became a formal API RAGAGAP, thought leaders like John Aller were discussing the need for operational affects on fixed asset end of life.

Integrating RBMI With Your ERP

Examine how consolidating the master equipment list into SAP, and integrating RBI eliminated $56k in annual costs but more importantly, mitigated human error in something as simple as data entry, that could potentially contribute to a catastrophic event.

Application of a Risk-Based Program to Optimize Relief Valve Maintenance

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This paper examines the financial benefits and more importantly, the risk reduction benefits of RBI compared to a conventional API-570 inspection program.

Integrating Risk Based Inspection with Fitness for Purpose

Risk Based Inspection (RBI) was a relatively new technology in 1996. This paper provides some of the earliest benefit analyses for RBI following the completion of the base resource document that eventually became API 580 by one of the same authors of this paper.

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This paper compared the number of TMLs required for a traditional time based inspection program with risk based inspection and the resulting savings.

Using Risk Based Inspection to Focus on Corrosion Under Insulation

This paper discusses how inspecting for CUI could be better refined using a semi-quantitative RBI model.

Risk-Based Inspection, From New Technology to RAGAGEP

This presentation discusses the the transformation of RBI as a base resource document to a Recognized and Generally Accepted Good Engineering Practice.

Integrating Risk Based-Inspection with Fitness for Purpose

Risk Based Inspection (RBI) was a relatively new technology in 1996. This paper provides some of the earliest benefit analyses for RBI following the completion of the base resource document that eventually became API 580 by one of the same authors of this paper.

Base Resource Document on Risk-Based Inspection: API Publication 581

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Risk-Based Inspection Methodology for the Petroleum and Petrochemical Industry

This paper represents some of the earlier collaborative efforts of two thought leaders in risk based inspection.

Materials Engineering and Risk Management in Chemical Plant Operations

The Publication discusses a study conducted at a 30 year old ethylene plant to optimize fixed equipment inspection and maintenance strategies prior to and during an upcoming planned shutdown.

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Related Training

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