CCD-IOW – REFINERY

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

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 Sales@E2G.com
www.E2G.com