Chemical Engineering May 2017 - 42

Cover Story
Implementing an
'Integrity Operating
Window' Program
Russ Davis
MISTRAS Group
IN BRIEF
DEFINING INTEGRITY
OPERATING WINDOWS
IOW PROGRAMDEVELOPMENT
OVERVIEW
DAMAGE
OR CORROSION
ANALYSIS
RISK RANKING
EVALUATING ALARMS
DEFINING THE IOW
CRITICALITY
501
DOCUMENTATION AND
TRAINING
IOW INTEGRATION
502
Hydrogen line
2
O.5
CO2 corrosion
Fuel gas
2
O.5
CO2 corrosion
500
Natural gas
2
O.5
CO2 corrosion
System
100
101
102
300
Description
Ammonia vapor
Ammonia liquid
Ammonia, CO2, H2O
vapor, ammonia recycle
High-pressure streams
Tail gas
Color
API 570
Pipe Class
1
2
2
2
Corrosion
rate, mil/yr
O.5
1
3
3
Damage
mechanism
NH3 SCC*
Ammonium
chloride corrosion
NH3
SCC
CO2 corrosion
Limits
Carbon steel in aqueous
ammonia non-PWHT*
Concentration of ammonium
salts and temperature
Carbon steel in aqueous
ammonia non-PWHT
<300°F
Liquid phase where CO2
condenses from vapor
phase
<300°F
Liquid phase where CO2
condenses from vapor
phase
<300°F
Liquid phase where CO2
condenses from vapor
phase
<300°F
Liquid phase where CO2
condenses from vapor
phase
A
42
comprehensive asset-integrity
management (AIM) program is essential
to ensuring process integrity
and reducing risk of operations
to as low a level as practicable. Historically,
these programs are based on a given set
of operational parameters that were established
during the implementation of
the program. To develop these programs,
process conditions - such as the various
chemical components present in the process
streams, temperature, pressure, and
flowrates - are analyzed by mechanical inFIGURE
1. Damage mechanisms are established to identify
the key controllable monitoring parameters, or variables that
can be effectively adjusted to bring the process back within
safe operating limits (*SCC = stress corrosion cracking;
PWHT = post-weld heat treatment)
tegrity (MI) subject matter experts (SMEs).
These experts identify the potential damage
mechanisms associated with anticipated
operating conditions, and help to establish
inspection methods and testing frequencies.
In the subsequent management of the
AIM program, reliability and MI groups rely
on these parameters and testing methodCHEMICAL
ENGINEERING WWW.CHEMENGONLINE.COM MAY 2017
Part 1
An effective Integrity Operating Window (IOW) program - which establishes safe operating
limits and acceptable limits of process variation before an asset begins to degrade - can help
operators stay ahead of potential repairs and reduce risk

http://WWW.CHEMENGONLINE.COM

Chemical Engineering May 2017

Table of Contents for the Digital Edition of Chemical Engineering May 2017

Contents
Chemical Engineering May 2017 - Cover1
Chemical Engineering May 2017 - Cover2
Chemical Engineering May 2017 - Contents
Chemical Engineering May 2017 - 2
Chemical Engineering May 2017 - 3
Chemical Engineering May 2017 - 4
Chemical Engineering May 2017 - 5
Chemical Engineering May 2017 - 6
Chemical Engineering May 2017 - 7
Chemical Engineering May 2017 - 8
Chemical Engineering May 2017 - 9
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Chemical Engineering May 2017 - Cover3
Chemical Engineering May 2017 - Cover4
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