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.     

安全设备失效数据获取与计算

安全设备失效数据是安全仪表系统(SIS)分析、设计和维护等活动所需的基础数据信息,对安全仪表系统的开发和功能安全相关标准的实施至关重要。文中总结分析了国内外现有失效数据库的现状,详细介绍了OREDA数据库。研究阐述了设备失效的类型、失效因素和数据的获取要求,讨论了失效数据质量的主要影响因素,研究提出了FMEDA失效数据获取法、现场数据获取流程以及失效率的几种计算方法,给出了失效数据信息的表示形式。     

Equipment selection for the optimal system unavailability of jacketed reactors with discrete cost data

This study introduces a method that selects equipment, so as to reach the required unavailability level, by carrying out an optimization analysis which considers the reliability data and cost of the equipment. A more practical optimization problem has been formulated using the objective function based on the discrete function and constraints.For the cooling system of a jacketed reactor, an optimization analysis was performed on equipment that have different failure rates depending on their costs in order to reach the target unavailability level required by the system. The integer programming was used for this optimization analysis. When the method developed through this study is used, cost can be reduced and the target level of the system unavailability can be reached by selecting proper equipment for chemical plants through the optimization analysis. This is more cost efficient than the former method of selection, which does not perform any economical analysis thus leading to the usage of overly expensive equipment with low failure rates.     

船舶设备事故中的人为因素分析与控制研究

根据设备维修系统设备维修的人为失误环节和船员失误分析模式以及轮机管理人员具有明感知设备的运行状态、隐感知设备的故障趋势等特点,实施有效管控措施。结合航运市场特性,基于设备可靠度,提出风险性和经济性的维修方式策略,可大幅提高航运公司的安全航运水平和经济效益。利用维修系统的信息流,建立了船舶设备维修管理信息系统,整合设备运行状态、船员的综合素质状态及组织管理信息,以便于阻断导致事故发生的事件链,提高航运公司的船舶运输安全。     

污水处理厂设备维护管理优化研究

以JL污水处理厂设备管理优化过程为例,充分吸取LCC,TPM中的先进思想,以设备运行可靠性及设备维护经济性为追求目标,建立了设备管理优化体系。流程体系上,通过建立作业指导文件,建立标准化维修程序,对于操作过程及时进行记录,建立可视化、可追溯的管理方法;指标体系上,根据设备重要性及运行状况,确定设备风险指数,分级管理;建立控制指标,并动态调整;管控体系上,建立设备“户口”,对设备的维护、保养、使用等信息进行全面登记;考核设备维护的全面性、及时性、可靠性、合规性;重视设备维护的预计与预警;技术体系上,通过设备监测仪器的使用,对设备运行状况定量化。通过不断推进设备预防性维护工作,设备完好率不断提升,仪表完好率从2016年的97.34%,96.55%水平,分别提升至99.08%,98.72%;维护费用也保持在较低水平,检修费与资产比例在实施的前两年分别降至1.49%,0.85%,实现了污水处理厂节能降耗及运行可靠性的强化。     

A data mining approach to deriving safety policy implications for taxi drivers

Introduction: Traffic safety issues associated with taxis are important because the frequency of taxi crashes is significantly higher than that of other vehicle types. The purpose of this study is to derive safety implications to be used for developing policies to enhance taxi safety based on analyzing intrinsic characteristics underlying the cause of traffic accidents. Method: An in-depth questionnaire survey was conducted to collect a set of useful data representing the intrinsic characteristics. A total of 781 corporate taxi drivers participated in the survey in Korea. The proposed analysis methodology consists of two-stage data mining techniques, including a random forest method, with data that represents the working condition and welfare environment of taxi drivers. In the first stage, the drivers’ intrinsic characteristics were derived to classify four types of taxi drivers: unspecified normal, work-life balanced, overstressed, and work-oriented. Next, priority was determined for classifying high-risk taxi drivers based on factors derived from the first analysis. Results: The derived policies can be categorized into three groups: ‘the development of new policies,’ ‘the improvement of existing policies,’ and ‘the elimination of negative factors.’ Establishing a driving capability evaluation system for elderly drivers, developing mental health management programs for taxi drivers, and inspecting the taxi's internal conditions were proposed as new policies. Improving the driver's wage system, supporting the improvement of rest facilities, and supporting the installation of security devices for protecting taxi drivers are methods for improving existing policies to reinforce the traffic safety of taxi drivers. Last, restricting overtime work for taxi drivers was proposed as a policy to eliminate negative factors for improving taxi traffic safety. Practical Applications: It is expected that by devising effective policies using the policy implications suggested in this study, taxi traffic accidents can be prevented and the quality of life of taxi drivers can be improved.     

Frequency data and modification factors used in QRA studies

The source data for QRA’s is important to assure meaningful risk assessment results, particularly when the result is to be compared against quantitative risk acceptance criteria. The author’s company is one of the largest global QRA providers and we have concluded that the UK HSE Hydrocarbon Release Database (HCRD) provides the basis for the best leak frequency data as it offers complete leak data collection in a systematic manner, against a known population of equipment and facilities in the UK sector of the North Sea for which there is an accurate parts count estimate. The LEAK program is described. It screens HCRD to remove leak events not associated with full operations inventories and flows (e.g. when isolated for maintenance) and further uses a distribution function that permits frequencies for any arbitrary hole size range to be determined (e.g. 25 mm leaks, 50 mm leaks, full-bore ruptures). An important factor is that leak frequency data is not stationary, offshore operators have improved their control of leak events and the HCRD shows a declining leak rate over time.DNV often uses frequency modification techniques, termed MOR - Modification of Risk. This paper reviews 4 methods developed by the company internationally. These are the Manager Method, the API 581 method, a barrier based method, and a proprietary management system based method. These all permit localization of UK North Sea data to apply to other facilities (onshore or offshore) and with different management systems and mechanical integrity programs.Overall, localized data using MOR is considered more accurate than direct use of UK North Sea data, however validation is an issue. There are no direct comparisons that compare leak statistics over a sufficiently long period with static management systems and integrity programs. Thus MOR techniques remain judgment based approaches, but transparent in methodology and assumptions. The barrier based modification technique is the most directly verifiable of the four MOR methods presented.     

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.     

污染源水质自动监测系统数据质量保障措施研究

近年来,在我国工业化规模不断扩大、工业项目不断增多的影响下,水资源的污染问题愈发严峻,对人们的生命健康安全造成了巨大影响。所以,水质监测部门要充分利用先进的水质监测技术和设备,对污染源水质实施连续不间断的监测,有效提高水质监测数据质量。本文主要提出了几点保障污染源水质自动监测系统数据质量的措施,供相关人员借鉴采纳。     

新型机车监控系统的研究

设计了一种基于GSM的机车监控系统。用无线电手机传输监控装置产生的原始数据至PC机 ,来达到实时监控机车运行状况的目的。实践表明 ,该系统简单灵活 ,传输可靠 ,具有良好的稳定性和可靠性。与现行车载监控装置相比 ,新型机车监控系统具有提高数据的实时性、减轻工作人员的劳动强度等优点     

铁路真空卸污设备远程运行维护系统设计

以铁路真空卸污设备为研究对象,进行远程运行维护系统的开发设计。根据真空卸污设备的运行特点,确定系统具备的功能,采集的数据类型、信号传输方式,并进行硬件开发集成和软件开发。该系统可以实现对铁路真空卸污设备运行状态数据的采集与分析,加快真空卸污设备故障诊断和维护的响应速度,提高设备的安全性和可靠性,提升铁路真空卸污设备运行维护智能化水平。     

改进的DEMATEL法在航空公司外委维修安全风险分析中的应用

为有效识别和分析外委维修安全风险因素间复杂的影响关系,提出了群决策DEMATEL分析方法。该方法以语言变量和三角模糊数之间的转换为基础,通过群决策理论集结专家信息建立直接影响矩阵;利用DEMATEL分析法对外委维修的安全风险因素进行辨识,实现定性定量相结合的分析。以某航空公司为例,采用该方法分析了14个对外委维修安全影响显著的风险因素。结果表明,在外委维修过程中,航空公司和承修商应重点监控7个原因型因素和中心度排序靠前的6个因素。     

Risk-based maintenance policy selection using AHP and goal programming

Maintenance policy selection is a multiple criteria decision making. The criteria often considered are cost and reliability of maintenance. There has been a growing interest in using risk of accidents as a criterion for maintenance selection. This paper presents an approach of maintenance selection based on risk of equipment failure and cost of maintenance. Analytic hierarchy process (AHP) and goal programming (GP) are used for maintenance policy selection. A case study in a benzene extraction unit of a chemical plant was done. The AHP results show that considering risk as a criterion, condition based maintenance (CBM) is a preferred policy over time-based maintenance (TBM) as CBM has better risk reduction capability than TBM. Similarly, considering cost as a criterion, corrective maintenance (CM) is preferred. However, considering both risk and cost as multiple criteria, the AHP–GP results show that CBM is a preferred approach for high-risk equipment and CM for low risk equipment.     

Reliability and availability modeling of Subsea Xmas tree system using Dynamic Bayesian network with different maintenance methods

Subsea Xmas tree is a vital equipment for offshore oil and gas development. Aiming at the fault mode of subsea Christmas tree system under production conditions, the fault tree of subsea tree system was established, which was transformed into Dynamic Bayesian network, and the reliability and availability of subsea tree system with different repair states are quantitatively analyzed. In this paper, the DBNs are partially verified by the method based on three axes. The results show that the reliability of subsea vertical tree system is slightly higher than that of subsea horizontal tree system. After repair and maintenance, the performance of subsea tree system has been significantly improved, and the improvement of the system performance by preventive maintenance is more obvious. Compared with the perfect repair, the performance of the system with imperfect repair is not significantly reduced. Compared with perfect repair & preventive maintenance, the performance of the system with imperfect repair & preventive maintenance is slightly reduced. In addition, the influence of failure rates and degradation probability on reliability and availability is analyzed. By comparing the influence of failure rates on the system performance of non-maintenance and maintenance, it is found that the change of failure rates has the greatest influence on the reliability and the least influence on the availability of perfect repair & preventive maintenance. By comparing the performance of each component in the subsea tree system, it is found that the failure rates has the most obvious influence on the chock module, and gate valve and tree cap have the most significant influence on the reliability of the system. In order to improve the reliability of subsea tree system, it is necessary to improve the reliability of chock module, gate valve and tree cap.     

煤矿安监系统数据通信可靠性的研究

煤矿安全生产监控系统的通信网络可归纳为单分站单设备、单分站双设备、双分站单设备和双分站双设备几种组网模式,通过对其任务可靠性和基本可靠性进行比较分析,综合考虑任务完成概率和维护成本两方面的要求,提出了双分站,局部(高故障点处)双设备的组网模式,以期有效提高通信网络的系统可靠性。     

基于马尔可夫的地面控制井下安全阀可靠性评估

为保障地面控制井下安全阀系统的安全运行，防止系统发生故障，建立了井下安全阀可修复系统的马尔可夫模型；针对系统设备构成复杂及共因故障等问题，基于β因子模型描述共因失效，同时将模型划分为3个独立模块，通过克罗内克积方法合并，评估系统可靠性；参照OREDA可靠性数据，定量求解井下安全阀系统可用度、可靠度以及稳态指标，研究模型中状态转移概率对系统稳态可用度的影响。研究结果表明:井下安全阀系统的可用度随时间增长而迅速到达稳态值；系统检修周期应小于2.5 a；根据可靠性分析结果，运营方应考虑系统经济与可靠性间的博弈关系，合理优化系统冗余结构与维修周期管理，防止井下安全阀系统失效。     

Development of a risk-based maintenance (RBM) strategy for a power-generating plant

The unexpected failures, the down time associated with such failures, the loss of production and, the higher maintenance costs are major problems in any process plant. Risk-based maintenance (RBM) approach helps in designing an alternative strategy to minimize the risk resulting from breakdowns or failures. Adapting a risk-based maintenance strategy is essential in developing cost-effective maintenance policies.The RBM methodology is comprised of four modules: identification of the scope, risk assessment, risk evaluation, and maintenance planning. Using this methodology, one is able to estimate risk caused by the unexpected failure as a function of the probability and the consequence of failure. Critical equipment can be identified based on the level of risk and a pre-selected acceptable level of risk. Maintenance of equipment is prioritized based on the risk, which helps in reducing the overall risk of the plant.The case study of a power-generating unit in the Holyrood thermal power generation plant is used to illustrate the methodology. Results indicate that the methodology is successful in identifying the critical equipment and in reducing the risk of resulting from the failure of the equipment. Risk reduction is achieved through the adoption of a maintenance plan which not only increases the reliability of the equipment but also reduces the cost of maintenance including the cost of failure.     

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。     

Reliability data acquisition and evaluation in process plants

Based on the practical experience of assessing reliability data in two plants of the explosives industry, the organization and scope of the data collection, the component delimitation, the procedures of quality assurance and the data evaluation for their final use in PSA studies are presented. An example is given for the type of detection and repair, etc. The mathematical background for evaluating observed component lifetimes is discussed. Both frequentist and Bayesian methods are addressed. The resulting failure rate distributions and their approximations by log-normal distributions for several key components are presented. They were obtained using a Bayesian approach with a non-informative prior. Remarks on uncertainty, their treatment and a proposal for transferring data to plants other than the ones investigated conclude the presentation.     

基于危险工艺装置设置安全联锁系统的研究

针对危险工艺装置设置安全联锁系统(SIS)问题进行分析和研究,提出在装置建设和改造中,应合理设置独立的SIS,并根据生产装置的安全度等级选择合适的联锁回路,并具有一定的冗余能力,以避免由于硬件随机失效或系统故障时造成联锁功能无法执行;指出SIS在设计时应遵循独立原则、故障安全型原则、共享原则、可靠性原则等。研究结果表明:SIS可提高化工装置的本质安全度,保障生产过程的安全、稳定运行,最大限度地减少由于过程失控造成的人身伤害和设备损坏。