NEW LOGO

Capability
Statement

Integrity Operating Windows

Plant and Topside Facilities

Integrity Operating Windows (IOWs) for Plant and

Topside Facilities
Wood Group Integrity Management (WGIM) has the experience and in-depth technical
knowledge to develop Plant and Topside Facilities comprehensive corrosion management
programs.
Processes are not always stable either through upsets or feedstock variations. These
excursions are typically not considered and their impact not examined in standalone RBI
assessment. WGIM proposes IOW development to ensure your asset integrity
management plan is effective. We believe that process surveillance within the right IOWs is
a vital component to complement RBI assessment and inspection planning.
The American Petroleum Institute (API) has issued a
new recommended practice API RP 584 that discuss
the need to establish operating limits that address the
controls necessary for process variables that might
affect the integrity or reliability of the process unit.
WGIM recently developed integrity operating windows
for several WA Oil & Gas companies. The potential
damage mechanisms for every vessel and corrosion
circuits were evaluated, during the RBI assessment.
For each applicable damage mechanism, limits were
established on critical process parameters to keep the
process into boundaries to ensure integrity of pressure
equipment. In many cases, the limits were chemical,
related to the composition of the process stream
because of its impact on corrosion. In other cases, the
limits were physical both because of corrosion impact
and effect on mechanical properties.

What are IOWs?

The RBI assessment determines frequency and scope
of inspection by identification of susceptible damage
mechanisms on pressure equipment. It assumes the
application of reliable monitoring of critical process
parameters to minimize damage to equipment that may
be associated with process and design excursions.
IOWs are those preset limits on process parameters
that need to be established and implemented in order
to prevent from potential material degradation.
Operation within the recommended limits should result
in predictable and reasonably low rates of degradation
or prevent damage initiation and propagation.
Conversely, operation outside the IOW limits could
result in unanticipated damage or accelerated damage.
Potential breach of containment could result from one
or more damage mechanisms covered in API RP 571
including general or localized corrosion, mechanical or

NEW LOGO

metallurgical damage, high temperature corrosion and

environmentally assisted cracking.
IOWs establish a safe operating regime for equipment

Design Limits
Process and
Economic Limits
Integrity Operating
Window Limits
Defining, Monitoring and Maintaining IOWs
Typical parameter requiring IOWs
WGIM possesses knowledge and experience to
define process parameters that need IOWs to monitor
damage mechanisms identified during the RBI.
Exercise of defining IOWs can be done during RBI
workshop, particularly in the presence of process and
or chemical experts.
Chemical parameters are those related to the
chemistry of the process stream, as pH, water
content, oxygen content, chloride level, acid gas
loading, chemical concentration

spreadsheet and good communication with operator.

However, an IOW surveillance software would provide
real time monitoring, and automate alerting process.
WGIM have experience in developing
and
implementing software to manage IOWs surveillance.
In doing so, we identify the right parameters to monitor,
the most relevant source of data, and appropriate
levels of alarm. We also challenge definition of
corrective actions, allowed time in exceedance and
responsibilities. We produced specific dashboards to
facilitate visualization and trending of IOWs, and
defined key performance indicators for a major
operator in Oil & Gas industry.
Maintaining IOWs
Similarly to the RBI process, the IOWs surveillance is a
live process. We facilitate workshops to periodically
review the IOW surveillance outcomes.
The IOW list should be updated to account for process
change, exceedance feedback, inspection results, new
information about degradation mechanisms.
A Management of Change process should be applied
whenever IOWs are being revised or updated. We can
assist in redefining IOW surveillance procedures to
maintain its efficiency.

Design Data

Physical parameters include other aspect of the

process to maintain operation within design, as
pressure, temperature, dew point, heating and cooling
rate, cycling operation, flow velocities, corrosion
probes measurement.

Pressure/temperature
Materials
Process limits

Metallurgical
and
Corrosion
Data

IOWs (limits) are classified into different levels,

distinguished by risk, in order to set priorities on
notifications and timing of corrective actions to
escalate
when
IOWs
are
exceeded.

RBI Assessments
Corrosion Circuits
Damage Mechanisms
Material Limits

Process and
Reactive
Chemistry

Pressure/temperature
Process limits
Operating manuals
Laboratory Test data

Monitoring IOWs
Source
of
data
for
process
parameters
values is multiple. It
usually
varies
form
laboratory
testing
on
samples, instruments, online
analyzers, corrosion probes
and coupons. The IOW study might
recommend additional monitoring from existing ones
to complete the surveillance.
IOWs monitoring or also called surveillance, is
achieved by accessing on live and trending
parameters to make sure process remains within
IOWs. Excursions are notified and appropriate
corrective action raised.
This exercise can be manual and rely mainly on

Industry standards

Recommended
Company standards
Practice

Regulatory requirements

Subject
Matter
Expert Inputs

Operational
History

Plant
Equipment

Materials and Corrosion

Process Chemistry
Limits

Production
Maintenace
Inspection
Integrity/Reliability

Vessels and piping

Tags - Sample points,
sensors
Sensors and analysers

NEW LOGO

How RBI and IOW are linked?

Why IOWs are important?

RBI studies are based on assumptions regarding past

and future operating conditions, and are focused more
on inspection planning, than on controlling current
operations and monitoring activities.

A
fundamental
understanding
of
the
process/operating conditions and resulting damage
mechanisms are required in order to establish and
maintain an inspection program that yields the
highest probability of detecting potential damage.

An IOW surveillance system provides monitoring of

critical process parameter and identify upset
conditions that lead to accelerated damage. The IOW
program complements RBI and helps a RBI plan to
succeed. Together, these two methodologies provide
an improved chance for integrity and safety. IOWs can
be created during or after RBI is implemented, but a
standalone study is also possible.
Distinguish IOW from other acronyms
Various IOW formats have been established over
recent years and are often referred to by different
acronyms. Examples of some of these documents
include Material Operating Envelopes (MOEs); Critical
Process Variables (CPVs); Corrosion Manuals;
Corrosion Control Documents (CCDs) and many
others. They vary in scope, detail and complexity but
comply with the overall intent and spirit of the IOW
methodology.
At WGIM, we are aware of existing monitoring
programs our clients are using, such as instruments
wired to Central Control Room. Usually, the intent is to
monitor reliability and operation within design
temperature and pressure. The IOW surveillance we
expose here is not duplicating as it targets parameters
that drive damage mechanisms susceptible to cause
breach of containment.

Inspection plans should be dynamic and account for

changing process conditions and current equipment
condition. Using IOW it is essential to identify and
track process information that validates or might
cause changes to existing inspection plans.
API RP 580 Risk Based Inspection - Section 7.4
states: Operating within the boundaries is
fundamental to the validity of the RBI study as well
as good operating practice. It is vital to establish
and monitor key process parameters that may affect
equipment integrity to determine whether operations
are maintained within boundaries (i.e. IOWs).
The personnel footprint on certain facilities could be
restrained. Much of the technical expertise could be
remote to the facilities and needs decision support
tools for quality and timely decision-making,
particularly in relation to process safety
management. The IOW surveillance is a good
decision support tools.
IOW study case
Example of potential process parameters for IOWs for
a generic amine process unit
Amine concentration
Water content
Rich amine, lean amine gas loading
Velocity in rich amine piping
Reboiler temperature
Heat Stable Salts (HSS) concentration