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How To Perform A Damage Mechanism Review
How To Perform A Damage Mechanism Review
INSIGHT
This article was adapted from the paper, "Effectively Addressing the Results of Damage Mechanism Reviews in a
Process Hazard Analysis: A Checklist Approach," which was presented at AIChE's 13th Global Congress on
Process Safety in March 2017.
Performing damage mechanism reviews (DMRs) to determine credible degradation modes and susceptibilities of
processing equipment has become an important step in developing effective mechanical integrity plans in the
refining and chemical processing industries. DMRs aid in formulating inspection plans to mitigate risk from loss of
containment and/or unplanned outages and are the subject of the corresponding API Recommended Practice (RP)
571. In addition, California OSHA's (Cal/OSHA's) recently revised Process Safety Management (PSM) for Petroleum
Refineries regulation now requires that DMRs be performed and process hazard analyses (PHAs) address DMR
reports that are applicable to the process unit being analyzed.
The following process for performing DMRs includes insights from our Safety, Risk and Compliance team.
2. Develop Information
A DMR includes (1) generating a corrosion materials diagram, (2) preparing a DMR worksheet, (3)
identifying initial corrosion loops, and (4) identifying potential damage mechanisms.
Developing corrosion loops is an important step in performing a DMR. A corrosion loop is defined as a
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section of a process that shares common damage mechanism susceptibilities with similar anticipated rates
of damage. A corrosion loop is typically comprised of similar materials exposed to similar
process/environmental conditions and asset characteristics (materials of construction, insulation type,
coatings, heat tracing present, buried, etc.).
Corrosion loops are developed using the following guidelines:
Maintain a single process chemical (for example, a major indication of a loop boundary is when the service that
is flowing through the piping undergoes a change that greatly affects the composition)
Maintain a single phase
Use the inlet/outlet of a major piece of equipment (pressure vessel, separator, heat exchanger, column, etc.) as
a loop boundary
3. Conduct DMR
A DMR team typically includes a corrosion engineer/specialist, unit inspector, unit process engineer, unit
operations representatives, unit mechanical/reliability engineer, unit subject matter experts for licensed
technologies (if needed), and a facilitator knowledgeable in the DMR process. The team (1) conducts a
process overview, considering operating and maintenance procedures, and (2) collects unit-specific process
data and discusses mechanical failure history.
The steps in conducting a DMR include:
1. Developing color-coded process flow diagrams (PFDs) to illustrate various corrosion loops in each process.
PFDs, P&IDs, piping isometric drawings, and process stream heat and material balances are normally used to
generate color-coded PFDs.
2. Collecting materials of construction and fabrication records to be added to the PFDs so corrosion
materials diagrams (CMDs) can be developed. The CMD is a modified process flow diagram or
database containing relevant equipment and piping corrosion mechanisms, operating conditions,
materials of construction, and corrosion circuits.
5. Document DMR
A DMR report contains the information needed to understand materials damage issues in a specific type of
operating process unit at a plant site. The detailed DMR report includes corrosion loop drawings, corrosion
damage mechanism tables, and documented findings and recommendations from the DMR. It is
recommended that the report include the team member composition, the DMR approach, and data used in
performing the review.
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development, (2) corrosion monitoring location (CML) placement, (3) integrity operating window
development, (4) PHA meetings, (5) management of change reviews, and (6) incident investigations.
Complete the form below to request a copy of the full paper, "Effectively Addressing the Results
of Damage Mechanism Reviews in a Process Hazard Analysis: A Checklist Approach."
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