Integrity Operating Window (IOW) Program Implementation Plan

Phase 1: Foundation (Months 0-6)

Initial Assessment & Planning

• Conduct gap analysis of existing monitoring systems
• Identify critical process units and damage mechanisms
• Form IOW implementation team
• Process engineers
• Integrity/materials engineers
• Operations representatives
• Inspection personnel
• Management sponsors

Priority Equipment Selection

1. Crude unit
2. Hydrotreater units
3. FCC unit
4. Sulfur recovery units

Key Parameters for Monitoring

• Temperature
• Pressure
• Flow rates
• pH
• Sulfur content
• TAN (Total Acid Number)
• Water content
• Chlorides
• H2S concentration
• NH3 levels

Phase 2: Development & Pilot (Months 6-12)

Establish IOW Limits

• Define four-tier system:

1. Standard operating range
2. Operation notification level
3. Management notification level
4. Shutdown criteria

Documentation Development

• Create IOW manual including:
• Parameter descriptions
• Measurement methods
• Response procedures
• Roles & responsibilities
• Review/update protocols

Pilot Program

• Implement on crude unit first
• Develop data collection systems
• Test notification protocols
• Refine procedures based on feedback

Phase 3: Full Implementation (Months 12-24)

Technology Infrastructure

• Install/upgrade monitoring systems
• Online analyzers
• Data historians
• Automated alerts
• Dashboard development

Training Program

• Operator training modules
• Engineer certification
• Management awareness sessions
• Contractor orientation

Roll-out Schedule

1. Crude unit (Month 12-14)
2. Hydrotreaters (Month 14-16)
3. FCC unit (Month 16-18)
4. Sulfur units (Month 18-20)
5. Remaining units (Month 20-24)

Phase 4: Optimization & Sustainability (Ongoing)

Performance Metrics

• Track key indicators:
• Number of exceedances
• Response time to alerts
• Equipment reliability improvements
• Maintenance cost reduction
• Inspection findings correlation

Review & Update Process

• Monthly team meetings
• Quarterly management reviews
• Annual program assessment
• Three-year major review cycle

Continuous Improvement

• Regular parameter validation
• Update limits based on experience
• Incorporate new technology
• Add/modify parameters as needed

Southern Climate Considerations

Temperature Management

• Account for ambient temperature variations
• Consider humidity effects on equipment
• Plan for extreme weather events
• Hurricane preparedness integration

Corrosion Monitoring

• Enhanced focus on atmospheric corrosion
• CUI (Corrosion Under Insulation) program
• Moisture control strategies
• Materials selection guidelines

Success Factors

Critical Elements

1. Management commitment
2. Clear roles & responsibilities
3. Effective communication protocols
4. Robust data management
5. Regular training & updates
6. Integration with existing programs

• Process Safety Management (PSM)
• Mechanical Integrity
• Management of Change (MOC)
• Risk Based Inspection (RBI)

Key Performance Indicators

1. IOW exceedance frequency
2. Response time metrics
3. Equipment reliability improvement
4. Maintenance cost reduction
5. Inspection finding correlation
6. Training completion rates

Documentation & Records

Required Documentation

1. IOW Manual
2. Parameter basis documents
3. Response procedures
4. Training records
5. Review meeting minutes
6. Management reviews
7. Incident investigations
8. Change management records

Data Management

• Historian configuration
• Alert system setup
• Trending capabilities
• Report generation
• Data backup protocols