基于RCM和RBI的设备寿命周期管理与应用

以可靠性为中心的维修(RCM)、基于风险的检验(RBI)和寿命周期费用管理(LCC)是目前国际上被广泛使用的设备管理技术.但是,它们还存在一些缺陷,如RCM、RBI都没有考虑设备在生命周期里的经济、技术状况以及运行状态的变化,实施的维修策略针对性不强;寿命周期费用管理又仅限于经济上的考虑,忽略对设备失效模式和失效后果的评估.为克服这些缺陷,并充分发挥它们的优势,提出了一种设备管理的新方法——基于RCM和RBI的设备寿命周期管理.该方法实际运用于某石化企业丁二烯车间动设备的管理之中,多数设备故障率和维修费用都因此明显降低,最终实现了设备寿命周期内科学有效的管理.     

以可靠性为中心的化工设备维修管理

<正>以可靠性为中心的维修RCM(Reliability-centred Maintenance)这一概念起源于美国民航领域,经过30多年的发展得到了不断地完善,其在电力设备、核电、石化、机械加工领域的技术日益成熟。化工设备的RCM是建立在对设备的设计特点、运行状态、故障模式及故障影响分析的基础上,以最大限度地提高设备的使用可靠度为目的,通过对设备的可靠性分析,     

石化企业安全链模型研究及应用

为增强石化企业安全管理能力,针对石化行业的特点、管理现状和国内外安全链理论的发展状况,运用系统思想并结合石化企业特征构建起融合安全要素和流程体系的安全链模型。安全要素由人、环境、信息、操作设备、运营设备、技术和管理等构成,流程体系由反映全生命周期的"提前行动、预防、准备、响应、恢复"等5个流程构成,2个维度的有机结合形成了安全链模型。运用该模型可以对影响石化企业安全生产的各要素和阶段予以准确定位。最后以宁夏石化公司为例,分析该模型在石化企业安全管理中的应用,实践表明其可以促进安全管理水平的提高。     

石化装置长周期安全运行风险分析和对策

随着国际竞争的激烈,石化生产装置的长周期运行成为我国石化企业的降本增效的主要手段。如何保证本质安全成为长周期运行的难题。本文以延迟焦化装置为例,主要从工艺原理、工艺原则流程和物料性质等方面进行了系统的风险分析,对设备利用英国TISCHUK公司的T-OCA软件进行RBI(Risk-based Inspection,即RBI)评估,确定了装置长周期运行存在的薄弱环节,并提出了控制措施。实践证明,该套方法对我国石化生产装置的长周期安全运行提供了科学的技术支持。     

基于FMEA的自动扶梯故障模式危害度研究

本文采用FMEA方法对自动扶梯各系统及部件的失效模式及故障原因进行了分析,建立了自动扶梯驱动主机、梯级链、导轨系统、扶手带等关键部件故障树模型,提出了重要部件故障危害度评估方法,研究了基于RCM的自动扶梯维护与检验技术,有利于实现自动扶梯科学维修,降低事故发生频率,对提高设备使用安全可靠性和智能运维管理能力具有参考作用。     

基于RBI技术的海上平台延期服役静设备定量化安全评估技术

针对海上延期服役平台静设备的安全风险评估与控制问题,应用RBI风险评估技术的评估理论和方法对海上延期服役平台静设备的定量化安全管理方法进行了实践和探索,并选择某延期服役平台进行风险分析相关结论的工程验证。其具体过程是运用定量RBI技术,首先根据工艺流程和介质特点对海上平台静设备分别进行了物流回路和损伤回路的划分,并以此为基础对延期服役平台静设备的安全风险进行定量评估,进而得出各静设备单元的失效可能性、失效后果及风险等级,最后通过得出的损伤模式、损伤机理及对应的腐蚀速率,从而制定针对性的检测策略。将利用这些检验策略所检测出的真实情况与分析结论进行对比,最终验证了RBI技术在延期服役平台静设备风险评估方面具有很强的适用性。     

基于RBI技术的储气库分离器风险分析

为应对储气库分离器日益复杂的工艺流程和逐步大型化的工艺设备,采用基于风险检验(RBI)的技术进行储气库分离器设备的风险分析。通过对分离器设备参数、运行参数和所处环境参数等多源异构数据进行搜集集成,构建分离器失效模型,计算分离器的失效可能性和失效后果面积,划分分离器的风险等级,从而制定分离器的检验周期和检验措施;将分离器RBI风险分析方法与先进的传感技术和大数据分析技术相结合,研发计算机辅助软件。结果表明:通过对分离器运行数据进行实时获取与处理,可实现RBI风险分析结果的精确性和自动化,从而提高储气库站场的安全管理水平。     

3D可视化石化装置安全管理系统的开发

本文介绍了3D可视化石化装置安全管理系统构成、功能和实验途径，该系统将三维激光扫描和GIS技术运用于石化行业，通过数据处理建立石化装置测绘级精度、全尺寸、全真实体的三维数字模型，并通过添加GIS信息和设备属性信息，实现石化装置5D可视化管理、分层管理、设备检维修和施工改造模拟、事故影响范围及应急救援最佳路径模拟、工作人员仿真培训等安全管理模块，为石化企业设备管理提供了新的技术平台。     

基于模糊数学的石化企业安全状况评估系统

针对石化企业安全信息存在模糊性和随机性的特点,提出了一个多因素多指标石化企业安全状况模糊综合评价算法,基于这种算法,设计了一个石化企业安全状况评估系统,以安全管理、工艺运行管理、设备运行管理、清洁生产、安全教育和人员素质等因素为系统的输入,运用模糊逻辑理论,结合专家评分,定量计算出石化企业的安全等级情况。系统充分考虑了多个安全因素对安全状况的影响,融合了主观判断和客观计算,解决了石化企业安全评价中多因素多指标带来的烦琐评价过程和复杂运算的问题,为石油化工企业的安全管理提供相关理论依据和实践支持。实际应用表明,其结果与实际情况较为符合,该方法可以较好的提高石化企业安全现状综合评价的客观性和准确性。     

美国石化企业的安全管理

强化法规1992年以来,美国不断加强和完善安全法规,收到了明显成效。1992年2月,美国职业安全卫生署正式颁布“过程安全管理规范”,完成了生产过程安全管理立法。该规范将技术、程序和管理实践融为一体,使过程安全置于优先地位,加快了以过程安全管理为核心的一系列安全法规───消防法、高压瓦斯取缔法、灾害对策基本法、劳动安全卫生法、化审法、灾害防止法等“六法”的实施步伐,从而使石化企业事故逐年下降。改进装备石化企业的设备故障是造成灾害事故的主要原因,因此选用良好的设备、材质、仪表,以及可靠的设备状态监测和自控自…     

Development and application of equipment maintenance and safety integrity management system

Equipment management in process industry in China essentially belongs to the traditional breakdown maintenance pattern, and the basic inspection/maintenance decision-making is weak. Equipment inspection/maintenance tasks are mainly based on the empirical or qualitative method, and it lacks identification and classification of critical equipment, so that maintenance resources can’t be reasonably allocated. Reliability, availability and safety of equipment are difficult to control and guarantee due to the existing maintenance deficiencies, maintenance surplus, potential danger and possible accidents. In order to ensure stable production and reduce operation cost, equipment maintenance and safety integrity management system (MSI) is established in this paper, which integrates ERP, MES, RBI, RCM, SIL and PMIS together. MSI can provide dynamic risk rank data, predictive maintenance data and RAM decision-making data, through which the personnel at all levels can grasp the risk state of equipment timely and accurately and optimize maintenance schedules to support the decision-making. The result of an engineering case shows that the system can improve reliability, availability, and safety, lower failure frequency, decrease failure consequences and make full use of maintenance resources, thus achieving the reasonable and positive result.     

成套装置动态风险管理专家系统

传统的设备管理模式造成设备非计划停机次数较多、故障频繁、可靠性和可用性不高等问题。为了解决上述问题,开发了成套装置动态风险管理专家系统,该系统包括动态风险监控、数据存储、失效模式及损伤机理判别、动态风险评估、风险辅助分析5个流程。该系统通过GIS平台进行展示,使用户可以直观、方便地查找、定位管线和容器位置,实现了高风险设备的风险展示、管道剩余寿命不足报警功能和管道冲蚀图例展示。将该专家系统进行了工程应用,得到容器和管道的潜在损伤机及其风险等级,针对不同风险等级的设备,生成了不同的检维修策略,为工程应用带来了很大的方便。     

海上平台静设备失效概率计算方法适用性研究

针对RBI评估失效概率计算方法对海上平台静设备的适用性,基于国内海上平台设备失效数据统计现状,提出以数据库软件为基础建立RBI评估系统的建议,以获取更加可靠的通用失效概率;对比国内外腐蚀减薄损伤系数计算方法的差异,根据海洋环境恶劣,静设备腐蚀严重的特点,结合模糊数学理论,提出更为保守的计算方法,并选取渤海某平台静设备验证新方法的适用性。结果表明,新方法得到的失效概率等级分布更为均匀,高失效概率等级的数量增多,符合海上平台静设备失效概率高的特点,但仍需通过生产实践来检验其可靠性。     

Management of life extension for topsides process system of offshore platforms in Chinese Bohai Bay

Technological advances in exploration and production mean that production platforms in Chinese Bohai Bay have many developments that are now operating beyond their original design life. As equipment ages, there are increasing challenges to maintain its integrity. Issues related to LE management of offshore facilities in government regulations, industrial associations and international oil companies were investigated. The results showed that emphasizing the requirements of labor union and industrial associations was a great feature in Norway, which was practical in Chinese Bohai Bay. Therefore, with the combination of the LE management system in Norway with the current situation in Chinese Bohai Bay, LE management model which integrates RBI, RCM, FMECA, and SIL risk assessment methods together was designed in order to improve understanding and ensure that LE issues were addressed across all aspects of asset management during the entire LE period. Finally, an example of three production offshore platforms on a gas field in the Bohai Bay was used to go through the LE management process and address the issues in each phase. The suggestions for improving LE management and technologies were given.     

Building an Executive Information System for Maintenance Efficiency in Petrochemical Plants—An Evaluation

This study used the manufacturing process in the petrochemical industries as an example and developed a dedicated maintenance programme and executive information system (EIS) for this industry. The software for EIS was established on a CMMS platform, with logical and extractive analysis used to store the information in a KPI databank. The system developed can provide plant managers and engineers with a complete summary of information and keep them updated regarding the present status of their maintenance efforts. The objective of this study was to establish a management system for maintaining knowledge in the petrochemical industries, such as the management of standard operating procedures (SOPs), historical records and the analysis of data for the facility. To design the software, a review of petrochemical facility was purposed to enhance the maintenance efforts and facilitate the decision-making process. The main functions of the system include asset reliability analysis, failure analysis and maintenance benefit cost analysis. For the petrochemical industry, the impact of safety and environment caused by equipment malfunction is more substantial than that of other industries. If executives can manage essential points effectively and make decisions according to a key performance index, risks to safety and environment, which result from equipment malfunction, can be decreased and safety can be enhanced for petrochemical refineries.     

石化企业应急救援能力评估研究

随着应急能力建设逐步引起我国各行各业的重视,越来越多的石化企业己经开始加大对应急能力建设工作的力度,以尽可能的减少生产事故所带来的损失。作为石化企业应急能力建设的重要组成部分,石化企业生产事故应急救援能力的评价研究具有十分重要的理论和实践意义。本文首先对石化企业生产及事故特点和石化企业应急能力进行了详细的剖析,初步构建了石化企业生产事故应急能力评价指标体系。进而根据物元可拓性理论,结合石化企业的实际情况,运用可拓评判方法建立石化企业应急救援能力综合评判的模型,给出了评价步骤,最终确定企业的生产事故应急能力等级,从而对企业持续改进应急能力建设提供一定的参考。研究结果表明,该方法可应用于多层次的工程风险评价问题,从而为石化工程项目风险管理提供了一种有效的分析方法。     

Study and application of Reliability-centered Maintenance considering Radical Maintenance

Radical Maintenance (RM) takes the root causes of failures as executive objects to make maintenance decisions. A Root Cause Analysis (RCA) is carried out on the function failure of equipment to perform RM and to create a maintenance plan using the combined methods of Failure Mode, Effects and Criticality Analysis (FMECA), and Fault Tree Analysis (FTA). Evaluation criteria and matrixes of criticality are used to evaluate the criticality level of failure modes. Moreover, Minimum Cut Sets (MCS) and importance calculation are applied to analyze the fault tree quantitatively. Based on our research, the concept and the analysis process of Reliability-centered Maintenance (RCM) considering RM are proposed and then applied to an actual engineering project in the petrochemical industry. The results of the application are presented through a maintenance strategy based on the project analysis by establishing the evaluation criteria and matrixes of criticality for petrochemical rotating machines and a fault tree of compressor vibrations. The direct causes of the induction of vibration faults in rotating machinery are classified according to the fault mechanism and frequency domain features in this paper. The research shows that using RM in the traditional RCM can help assign maintenance resources rationally and improve the quality of maintenance strategies.     

Cost–benefit analysis approach for the management of industrial safety in chemical and petrochemical industry

The high complexity of chemical and petrochemical installations determines a complex safety management of these establishments, therefore, there is a need to find innovative solutions to guarantee the prevention of failures and losses of containment from process equipment. In this frame, the use of the API Risk Based Inspection (RBI) assessment approach permits a significant reduction of maintenance costs and, simultaneously, the increase of plant's reliability and availability. To increase the level of industrial safety, a proper selection of measures is also needed, even if the adoption of such measures poses costs. Given that resources for the companies are usually limited, a comparison amongst various solutions has to be done with the aim to find the best one, based on a comparison of costs and benefit. To this scope, recently a software, named Inspection Manager, has been developed by ANTEA and implemented thanks to a cooperation with the University of Padova (Italy). The Inspection Manager provides support in the application of the RBI approach by means of the use of plant-specific data, which are stored in its database; its further implementation, presented in this paper, has made it able to support also cost-benefit analysis and, thus, the selection of measures to be adopted to prevent accidental events causing the release of hazardous materials. A case-study is presented to test the new functionality of the tool; after the identification of the most effective measures, a careful cost-benefit assessment has been executed as a basis for decision-making.     

基于可靠度理论的RBI修正模型研究

基于风险的检测技术包括定性RBI判断和定量RBI计算,定性判断得到风险相对的高低,风险相对较低者则不必进行定量RBI计算,风险高者再进行下一步定量RBI计算。在API581中,国外风险分析统计表明,石化企业的风险分布范围有一个所谓的"二八"现象,即"80%的风险是由20%的设备引起",中高风险以上的设备范围一般在20%左右。但我国十套装置风险分析结果发现,这个结论在我国并不适用,我国中高风险设备往往在40%左右。论文分析了API581在中国应用的局限性,引入可靠度理论计算设备失效概率,预估未来的失效概率或可靠度,可以完整地以RBI方法在得知失效后果和失效概率下,评估出此设备在整个系统中所处的地位,从而适当地分配检测、维修资源,在RBI完成后再进行风险评价进而完成风险评估过程。