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    20 - CCD Iow Refinery

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    RASHEED YUSUF
    This document discusses developing Integrity Operating Windows (IOWs) to promote predictable equipment damage rates and minimize leaks and unplanned outages at refineries. It provides an overview of how IOWs work, their key elements and goals of ensuring equipment is safely operated within established limits. Developing IOWs involves analyzing corrosion loops and damage mechanisms to set target and critical operating ranges. Stakeholder involvement is important and benefits include improved reliability, inspections and operations practices.

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    20 - CCD Iow Refinery

    Uploaded by

    RASHEED YUSUF
    135 views2 pages
    This document discusses developing Integrity Operating Windows (IOWs) to promote predictable equipment damage rates and minimize leaks and unplanned outages at refineries. It provides an overview of how IOWs work, their key elements and goals of ensuring equipment is safely operated within established limits. Developing IOWs involves analyzing corrosion loops and damage mechanisms to set target and critical operating ranges. Stakeholder involvement is important and benefits include improved reliability, inspections and operations practices.

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    20_CCD-IOW-REFINERY

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    This document discusses developing Integrity Operating Windows (IOWs) to promote predictable equipment damage rates and minimize leaks and unplanned outages at refineries. It provides an overview of how IOWs work, their key elements and goals of ensuring equipment is safely operated within established limits. Developing IOWs involves analyzing corrosion loops and damage mechanisms to set target and critical operating ranges. Stakeholder involvement is important and benefits include improved reliability, inspections and operations practices.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    135 views2 pages

    20 - CCD Iow Refinery

    Uploaded by

    RASHEED YUSUF
    This document discusses developing Integrity Operating Windows (IOWs) to promote predictable equipment damage rates and minimize leaks and unplanned outages at refineries. It provides an overview of how IOWs work, their key elements and goals of ensuring equipment is safely operated within established limits. Developing IOWs involves analyzing corrosion loops and damage mechanisms to set target and critical operating ranges. Stakeholder involvement is important and benefits include improved reliability, inspections and operations practices.

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    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    of 2

    CCD-IOW – REFINERY

    Q Why does the refining industry keep experiencing CCD Key Elements:
    significant failures from damage mechanisms
    that have been known for decades? • Corrosion Loop Drawings that link damage
    mechanisms to equipment (see example below)
    A The plant people who need to know about these • Tailored damage review specific to the unit’s
    damage mechanisms and how to avoid, control, operation, stream chemistry, and metallurgy
    and inspect for them have not had the adequate • Inspection, repair, and replacement highlights
    training or the knowledge transfer required to • Detailed assessment of existing metallurgy for
    understand the lessons learned in the past. anticipated future operation
    • Recommendations for effective inspection and
    Q My site has a robust inspection program. We replacement (if needed)
    follow the API inspection Code requirements. • IOWs = Recommendations (for Operations) to
    Why are we still having leaks? obtain predictable damage rates that will, in
    time, minimize leaks and unplanned outages
    A Analysis of many fixed equipment failures has
    shown that prolonged operation outside of
    recommended ranges is a key root cause.

    Have you considered developing


    Integrity Operating Windows?
    An IOW program will promote operation
    within controlled ranges, which leads to
    predictable damage rates.

    An E²G CL/DM/MOC
    style drawing shows
    corrosion loops, damage
    mechanisms, stress
    relief, and material of
    construction on a single
    drawing.

    CORROSION LOOP & DAMAGE MECHANISM LEGEND


    LINETYPE CORROSION LOOP/DM LINETYPE CORROSION LOOP/DM LINETYPE CORROSION LOOP/DM

    CL1 VACUUM OVHD VAPOR CL4 HOT HVGO >450F CL7 VACUUM HEATER

    CL2 LVGO CL5 OVERFLASH WASH OIL CL8 VAC HTR TRANS/TWR IN 1 5 6 20 23

    CL3 WARM HVGO <450F CL6 RUNDOWN CL9 VACUUM BOTTOMS 1 5 6 23

    K E YS TO F I X E D E Q U I P M E N T M E C H A N I C A L I N T E G R I T Y

    Design/Specify Build/Install Inspect/Analyze Maintain/Improve Operate/Monitor

    CCDs I OWs
    Promote proper design, construction, monitoring, Promote predictable
    inspection, and mechanical integrity improvement damage rates

    CCDs and IOWs are reliability tools that help move a plant organization from reactive to proactive.
    IOW Key Goals Development of CCDs & IOWs
    Operation within IOW limits is intended to result in predictable • Road map for developing CCDs is given in API 970 and for
    and reasonably low rates of equipment degradation. IOWs in API 584.
    • E²G follows a streamlined process to provide a concise and
    IOWs ensure good communication of equipment limits and easy-to-use product.
    exceedances between key Process, Operations, and Mechanical • Best results are obtained when all key stakeholders are
    Integrity personnel such that equipment can be safely managed fully involved.
    and operated without loss of containment.

    Operating Window Benefits of CCDs with IOWs


    A CCD with IOWs is a proactive tool that can support and improve
    plant organizations:
    Critical limit high Failure occurs quickly

    Failure occurs with Reliablity/Inspection


    Standard level high
    sustained operations
    • Where to inspect
    • How to inspect (what type of damage to look for)
    Target range high • Supports RBI
    • Supports root cause analysis for fixed equipment failures
    Stable, Safe to • Supports new designs
    Target Optimal
    reliable operate
    Operations
    Target range low
    IOWs
    • Set limits
    Failure occurs with
    Standard level high
    sustained operations
    • Establish integrity monitoring
    • Define action steps when outside limits
    Critical limit high Failure occurs quickly SOPs
    Operations practices to avoid/minimize damage during:
    Relationship between IOW limits and potential damage rates • Shutdowns
    • Downtimes
    • Start-ups
    IOW Key Elements
    • A list of the recommended IOWs Training
    • Recommended test or sample location and frequency
    for the IOW • Engineers, Operators, Inspectors
    • Recommended limits (Max/Min/Target) for the IOW • Understand how a process change or IOW impacts
    • Recommended API 584 IOW type (Informational/ damage mechanisms
    Standard/Critical) • Understand impacts when operating outside of desired
    • Possible consequences of IOW exceedances/deviations limits
    • Corrosion loop or loops impacted by the IOW
    • Recommended Operations/Process responses to IOW
    deviations
    • Recommended Inspection/SME responses to IOW deviations

    CORPORATE HEADQUARTERS SATELLITE OFFICE CONTACT


    20600 Chagrin Boulevard, Suite 1200 Houston, TX 216.283.9519
    Shaker Heights, OH 44122 [email protected]
    www.E2G.com

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