This section details the process of self and central engineering reviews of the CMP. The purpose of the reviews is to ensure that the CMP is efficient, effective and reliable, and that the work processes and activities are being implemented in accordance with the procedures. Review findings shall be used to improve the CMP and, where appropriate the corrosion management strategies.
A1. The scope of the reviews should provide:
Assurance that the CMP includes all essential elements as stipulated in this CMP Manual
Assurance that the implemented activities provide suitable barriers to the corrosion threats and suitable monitoring to measure performance
Assurance that the CMP activities are implemented in accordance with their documented procedures, and
Input into reviews of performance.
A2. Reviews shall be carried out in accordance with the checklist given in Table A1 and on the basis of objective evidence of compliance.
A3. Both internal and contractor led activity, e.g., chemical vendor, should be subject to this review.
A4. Self-reviews shall be carried out by the plant CMP Leader or plant corrosion engineer.
A5. Reviews shall be carried by the Central Engineering CMP Team Leader or Corrosion Subject Matter Expert assisted by another engineer, both with competence in review practice and understanding of corrosion management strategies.
A6. The Central Engineering CMP review team shall be independent of both operational and functional teams that are directly involved in implementing the CMP for the facility concerned.
A7. Reviews shall be carried out on a planned schedule developed by Central Engineering CMP Champion, as follows:
Reviews shall be carried out every 2 years
Self-reviews shall also be carried out every 2 years, 2 months prior to the review by Central Engineering.
A8. Central Engineering may bring forward a review if there is evidence of serious non-compliance that poses a threat to the effectiveness of the CMP and safety. In the event that non-compliance is detected, corrective action shall be agreed with the plant CMP leader or corrosion engineer and their management.
A9. Review reports shall be made available to the facility management and Central Engineering CMP Champion, his management, i.e., in this case Consulting Services Department (CSD) Manager and supervisors of the review team.
A10. Corrective action shall be recorded in the Central Engineering CMP Database that enables implementation, overdue actions and close out to be identified and tracked. Facility management and those responsible for actions shall receive regular reports from the Central Engineering CMP Champion on progress towards close out.
Table A1 - CMP Review Checklist
Corrosion Management Program Review
Date: Facility: By:
Item Question Yes/No Supporting evidence/ references and comments
A. Corrosion Management System
A1 Is there a documented corrosion system based on the corporate strategic work process “Manage Corrosion” at operate &
maintain phase of life cycle?
A2 Are you aware of the Corrosion Management Program policy defined in the CMP Manual?
B. Corrosion Competency
B1 Is there a trained and experienced corrosion engineer at your facility?
B2 Are you using a Competency Map (CMap) to monitor development, training and competency of your corrosion engineer?
B3 Does your facility have a plan of succession for your corrosion engineer?
C. Risk Assessment
C1 Has your facility developed corrosion loops and identified the damage mechanisms for all your plants/units?
C2 Does your facility perform corrosion risk assessments?
C2 Does your facility conduct investigations to identify root cause of all corrosion incidents?
C3 Has your facility adopted a risk-based inspection (RBI) program?
C4 Does your facility have a trained RBI facilitator?
Item Question Yes/No Supporting evidence/ references and comments
C5 Does your facility maintain a list of critical equipment and piping?
D. Corrosion Monitoring
D1 Does your facility have a Computerized Corrosion Management System (CMS)?
D2 Does your facility monitor corrosion using:
D3 Process variables (physical, chemical)?
D4 Probes?
D5 Coupons?
D6 In-Line Inspection/Smart Pigging?
D7 Does your facility maintain a fully functional SAIF system?
D8 Does your facility trend corrosion rate data and report this to management on a regular basis, e.g., monthly, quarterly, semi-annually, annually?
D9 Has your facility developed and makes use of Plant Integrity Windows to monitor corrosion management performance?
E. Chemical Treatment
E1 Does your facility monitor chemical and water injection rates and correlate with thinning/failure rates?
E2 Do you hold regular (weekly, monthly, quarterly, annually) review meetings with your Chemical Vendor?
E3 Are there KPIs targets defined for your Chemical Vendor?
E4 If yes, is your Chemical Vendor meeting the KPI targets?
E5 Do you investigate Chemical Vendor KPI target deviation?
Item Question Yes/No Supporting evidence/ references and comments
F. Corrosion Protection
F1 Does your facility have a coating (internal & external) and lining management program?
F2 Does your facility maintain a cathodic protection system?
G. Inspection
Does your facility maintain the following inspection programs:
G1 a. Injection Point?
G2 b. Corrosion under Insulation?
G3 c. Dead Leg?
G4 d. Positive Material Identification?
G5 e. Welding inspection?
G6 Does your facility apply the appropriate inspection method to the relevant damage mechanism?
G7 Are your Thickness Measurement Locations (TMLs) adequately defined and subject to periodic reviews?
H. Technology
H1 Do you think your facility has deployed sufficient/relevant technologies to manage corrosion?
I. Key Performance Indicators (KPIs)
I1 Has your facility developed and makes use of key performance indicators to manage corrosion failures?
J. Knowledge Management (KM)
J1 Is there a Corrosion Knowledge Management Program at your facility?
Item Question Yes/No Supporting evidence/ references and comments J2 Does your facility share failures or good corrosion engineering
practices with other facilities?
K. Documentation
K1 Does your facility maintain an electronic document management system (inspection reports, post-T&I reports, failure analysis reports, corrosion monitoring/trending, reports, etc.)?
Does your facility keep updated documents, as follows?
K2 a. SIS sheets
K3 b. PFDs
K4 c. P&IDs
L. Management of Change (MOC)
L1 Do you include all modifications (equipment, piping, water wash rate, inhibitor injection rate, welding repair, material changes, etc.) impacting corrosion in your MOC procedure?
M. Reviews
M1 Does your facility initiate a failure analysis request (to CSD) for all corrosion/mechanical failures?
M2 Does your facility keep an updated corrosion-related recommendation and technical alert tracking system?
M3 Does your facility perform internal periodic corrosion reviews to monitor compliance and eliminate corrosion failures?