Integrity Operating Windows (IOWs), which are developed as key operating parameters, identify factors such as process changes, new damage mechanisms as a result of changes in operating conditions, and acceleration of corrosion rates as a result of crude slate changes that may significantly affect the intended design life of your asset. When these changes take place, making the right decisions is facilitated by integrating IOWs with real-time corrosion models and mitigating actions.
Why do we develop integrity operating windows, IOW?
- When key process variables are affected by changes in operating conditions, new damage mechanisms may be introduced, which can have a significant impact on how long an asset will last.
- Even if based on risk, corrosion rates may accelerate as a result of changes in the crude slate or changes in velocity, and their impact on the asset may not be noticed until the next scheduled inspection.
- The actions necessary to reduce any newly imposed risk are identified by IOWs, along with potential process changes and operating conditions that may have an impact on remaining life.
- When these changes occur, incorporating IOWs and real-time corrosion models into your RBI program makes it easier to make the best decisions.
What do the major standards have to say about IOW?
- It may be beneficial to monitor important process parameters to determine whether operations are kept within bounds, according to API RP 580 Section 6.4.
- The likelihood of failure assessment “should be repeated each time equipment or process changes are made,” according to API 510 Section 6.2.
- API 584 – This second draft of recommended practices and guidelines for IOWs is being evaluated and has been in the works for a while.
What Owner/User/Operator want about IOWs?
Responsible business Owner Operators who are considering about implementing IOWs should make sure that the implementation that results follows the ongoing development of these standards and is in line with other industrial standards and best practices, including API 510, API 570, API RP 571 through 585, and API STD 653, as well as any internal standards and risk policies that come about as a result of the implementation.
What is the development process for the Integrity Operating Window?
Following a series of work process steps that are in line with the best practices of Owner Operators, Asset Optimization Consultants implements IOWs. AOC has work processes and procedures to supplement or deliver new, corporate IOW guidelines if these are not available. Based on historical operating and inspection data, the RBI plan and corrosion study make the assumption that all assets will be used in accordance with design specifications. The creation of IOWs has given your employees the tools they need to make sound decisions when your operating conditions change. The life of your asset is preserved over time.
In general, the process involves:
- supporting a team of key Owner stakeholders, including those from inspection, reliability, corrosion engineering, materials engineering, instrumentation, process, operations, and maintenance, in conducting an IOW review.
- Data collection is needed for a variety of reasons, including planned changes to operations and feedstock’s, corrosion studies, and maintenance records. In the absence of these, corrosion loops are created, and the instrumentation needed for IOW parameters is identified.
- IOWs will be prioritized based on a number of factors, including loss of reputation, production loss, the degree and location of risk and potential consequences as identified in the RBI study, and the impact on human health, safety, or the environment. If the process variable is exceeded, likelihood can be calculated using the RBI study or just the timeframe for an unacceptable event.
- Each IOW contains a suggested inspection or action from the operator, inspector, maintenance engineer, or reliability engineer.
- Remedial action implementation – When an IOW is exceeded during operation, the defined personnel can carry out the recommended corrective action in accordance with the IOW. The Reliability Engineering Department may also need to be informed as part of this action in order for it to decide whether further action, such as a fitness-for-service review, if required.
- IOWs should be integrated with other programs run by the facility, such as the PHA, RBI, MOC and, of course, Operations.
