Corrosion Prevention And Control Plan (CPC Plan)

By Michelle Otutu | Reviewed by Raghvendra GopalCheckmark
Last updated: May 26, 2023

What Does Corrosion Prevention And Control Plan (CPC Plan) Mean?

A Corrosion Prevention and Control Plan (CPC Plan) is a comprehensive strategy designed to prevent or minimize the impact of corrosion on equipment, structures and other assets.

The plan typically includes measures to identify, assess, monitor, and mitigate corrosion risks and establish maintenance, repair and replacement procedures.


Corrosionpedia Explains Corrosion Prevention And Control Plan (CPC Plan)

Corrosion is the gradual deterioration of metals and other materials caused by environmental factors such as moisture, chemicals and temperature changes. It can lead to structural failure, reduced efficiency and increased maintenance costs in various industries, including manufacturing, oil and gas, transportation and construction.

To develop an effective CPC Plan, engineers and corrosion experts use various techniques such as corrosion rate calculations, corrosion monitoring, material selection and protective coatings. These techniques involve formulas and calculations to estimate corrosion rates, evaluate the effectiveness of corrosion inhibitors and determine the optimal coating thickness and type.

For instance, the corrosion rate of a metal can be estimated using the following formula:

Corrosion Rate = (Weight Loss due to Corrosion)/(Surface Area x Time x Density)


  • Weight loss is measured in grams.
  • Surface is measured area in square meters.
  • Time is measured in hours or days.
  • Density is measured in grams per cubic centimetre.

By monitoring the corrosion rate, engineers can determine the remaining life of a metal component and schedule maintenance or replacement accordingly.

Other industry applications of corrosion prevention and control include:

Cathodic protection, for example, involves applying a DC current to the metal to counteract the corrosive effects of the environment, and chemical inhibitors, which are added to fluids or gases to reduce the corrosion rate.

To create a comprehensive CPC plan, the following steps can be taken:

  1. Identify assets and determine their corrosion risks. This is done by conducting a corrosion survey and assessing environmental factors such as temperature, humidity and chemical exposure.
  2. Develop a risk assessment matrix. This should prioritize assets based on their criticality and the severity of the corrosion risks.
  3. Develop a monitoring and inspection plan. This will help track corrosion rates and the effectiveness of corrosion control measures.
  4. Select corrosion control measures. Selection is done based on the asset's corrosion risks and criticality. This may include cathodic protection, coatings, corrosion inhibitors, or material selection.
  5. Develop a maintenance and repair plan. This should outline the frequency of inspections, testing, and maintenance activities, including repair or replacement of corroded assets.
  6. Train personnel. Personnel should know how to implement the CPC Plan and provide ongoing support for maintenance and repair activities.

Whole Building Design Guide (WBDG) offers a Corrosion Prevention and Control (CPC) Checklists Tool, which contains three editable checklists catered to planners', design engineers', architects' and sustainment professionals' needs for planning, designing and constructing facilities.




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