Utilizing Integrity Operating Windows (IOWs) for enhanced plant reliability & safety

Several industry codes, standards and recommended practices have been developed and utilized to maintain pressure equipment integrity and improve reliability. These industry standards focus heavily on inspections (time or risk based) and guidelines for operating equipment at conditions that enable a tolerable deterioration rate. RBI (risk based inspection), in effect, utilizes process conditions at a snapshot in time to recommend inspection strategies which can cover the span of the equipment's remaining life. On a day to day level, changes that occur in process conditions (excursions and upsets) are not fed back into the risk and criticality calculation. When such changes to operating conditions affect key process variables, new damage mechanisms could be introduced that affect the remaining life of an asset or accelerate existing damage mechanisms. The increase in risk resulting from these process changes goes unaccounted for until the effect of the deterioration is captured at the next inspection.Integrity Operating Windows (IOWs) are established limits for key process variables that can affect the integrity of the equipment if the process operation deviates from the established limits. The development of these IOWs requires fundamental understanding of the process and resulting damage mechanisms and is best facilitated by a team of corrosion and process engineers along with feedback from plant operators. A well-established IOW program is designed to provide real time notification of an increased risk to the integrity of an asset so that identified actions can be taken by the operators and/or plant managers proactively in a timely manner. Combining an RBI program with an IOW program can greatly increase its effectiveness and provide early recognition of equipment risks due to process changes. This paper will focus on the development of an IOW program and the benefits of combining it with a viable RBI program.     

加拿大油气管道安全管理体系及其启示

建立系统完善的安全管理体系是保障油气管道安全运行的基础。通过分析加拿大立法特点,梳理国家层面和地方层面管道安全监管机构设置与职责,研究管道安全法规体系,明确了加拿大油气管道安全监管体制和全生命周期安全管理体系。研究了管道企业安全管理体系和管道全生命周期各个阶段的关键工作,分析了行业协会在管道安全管理方面发挥的积极作用,掌握了管道完整性管理方面的经验与成果。在此基础上对中加油气管道安全管理情况进行了对比分析,从重视管道安全监管立法、建立全生命周期安全管理体系、完善油气管道标准规范、实施管道完整性管理、建立统一呼叫系统和管道地图系统、鼓励社会各方共同参与管道保护等方面提出了加强我国油气管道安全管理的建议措施。研究成果对于完善我国油气管道安全管理体系具有指导作用。     

腐蚀管道评价标准ASME B31G-2009和SY/T6151-2009对比

腐蚀是油气管道最常见的失效形式之一,对腐蚀管道进行剩余强度评价是保障管道安全可靠运行的基础工作。ASME B31G-2009和SY/T6151-2009是国内外的两种主流评价标准的最新版本,为了在选取适当的评价标准时有判断依据,比较分析了新版标准评价结果的保守程度,研究了评价流程、计算模型和计算参数取值等方面,并结合爆破试验数据和有限元仿真结果进行了验证。结果表明,两种标准仍具有一定的保守性,且当管道强度等级、腐蚀情况及数据资料完整度等不同时,两种标准有各自的适用范围和优缺点。     

基于Bow-tie模型的城镇输油管道风险评价方法研

根据近年来不断发生的城镇输油管道泄漏爆炸事故,提出将Bow-tie模型引入到风险评价中,将Bow-tie模型和改进的层次分析法相结合得出各影响因素的权重并排序,对管道进行风险评价,便于提出合理的安全管理方案,减少事故的发生。通过计算得到第三方因素在管道失效影响因素中占主导,而在事故后果分析中安全后果和环境后果因素影响较大,基本符合事故实际状况,说明该方法对于城镇输油管道风险分析有一定的指导意义和实用价值。     

天然气管道完整性管理探析

通过对国内外天然气管道事故的统计和分析,指出了对天然气管道进行完整性管理的重要性;在此基础上,简要介绍了管道完整性管理方法,着重探讨了天然气管道完整性管理的流程和环节,包括管道潜在危害辨识、管道数据信息搜集与分析、管道风险评价、管道完整性评价、完整性评价响应和减缓措施,并进一步说明了天然气管道完整性管理的实施方法;最后,给出了在我国开展天然气管道完整性管理的必要性和建议.     

Ageing management and monitoring of critical equipment at Seveso sites: An ontological approach

A safe “ageing” of Seveso establishments is a challenge for both operators and regulators. To this scope, Seveso III Directive required to integrate the equipment integrity issue into the safety management system for the major accident prevention; at the same time, the Italian Authority adopted a short-cut method for a quick ageing evaluation, which awards the application of the best techniques to control integrity and prevent deterioration-related failures. In this paper, the use of the ontology has been proposed to support decision-making about the implementation of technical solutions to control equipment ageing and comply the requirements of the Seveso legislation. To contrast deterioration mechanisms, the rapid development of data intensive smart sensors should be exploited and, in this frame, the automated on-line direct monitoring of equipment conditions, based on innovative low-cost sensors, is a novelty and promising solution. The developed ontology-based system points towards the adoption, when possible, of on-line monitoring. This solution provides much more data than traditional measurements and it is essential for the operators to understand how to merge concurrent information and data and to adequately control equipment deterioration. The ontology-based approach appears a viable solution even for this purpose. To demonstrate its potentiality, a real use-case has been used, where the model has been tested in finding the best technical solutions to improve the ageing management of an atmospheric distillation unit of a refinery in order to comply with safety requirements. A further use-case is given to show how the model can be used to react, after real-time damage signals, to restore safety conditions by means of an adequate decision-making.     

跨江大桥建设安全管理系统综合评价

针对目前我国重大工程建设的安全管理现状,以系统管理的思路借鉴国内外重大工程建设安全管理模式的先进之处,综合考虑影响重大工程建设过程中安全管理的各因素,建立6个一级指标,27个二级指标的评价体系。运用层次分析法(AHP)对其中指标进行权重计算,结果显示危险源辨识、危险源控制与管理是影响安全管理状况的主要因素;结合模糊综合评价法对泰州长江公路大桥的安全管理现状进行综合评价,结果显示为良好,与实际情况相符合,证明其可行性。该安全管理系统评价指标体系的建立与评价方法的运用,对重大工程建设的安全管理现状评价有借鉴意义,以期提高我国重大工程建设现场的安全管理水平。     

An integrated quantitative risk analysis method for natural gas pipeline network

Natural gas industry is developing rapidly, and its accidents are threatening the urban safety. Risk management through quantitative assessment has become an important way to improve the safety performance of the natural gas supply system. In this paper, an integrated quantitative risk analysis method for natural gas pipeline network is proposed. This method is composed of the probability assessment of accidents, the analysis of consequences and the evaluation of risk. It is noteworthy that the consequences analyzed here include those of the outside and inside gas pipelines. The analysis of consequences of the outside pipelines focuses on the individual risk and societal risk caused by different accidents, while those of the inside pipelines concerns about the risk of the economic loss because of the pressure re-distribution. Risk of a sample urban gas pipeline network is analyzed to demonstrate the presented method. The results show that this presented integrated quantitative risk analysis method for natural gas pipeline network can be used in practical application.     

基于多因素耦合的井筒完整性风险评价

为了合理开展井筒完整性评价,提出合理的管理措施,综合考虑管柱力学、管柱腐蚀、管柱及附件密封、水泥环力学、地层以及油气井管理等关键节点及因素的相互耦合协同作用,分析多因素耦合协同作用对井筒完整性的影响。对于管柱力学等具有比较明确物理意义且可以量化的因素,采用定量分析评价;对于操作管理等难以量化的因素采用定性评价,对于腐蚀环境因素采用定量与定性相结合的方法进行评价;在定性及定量评价的基础之上,对关键节点进行风险概率和风险影响程度的划分及量化,再基于层次分析及风险矩阵的方法建立井筒完整性评价模型;基于模型编制了相应的计算程序,并对某高腐蚀性气井开展了井筒完整性评价。评价结果表明,在影响该井井筒完整性的风险因素中,高酸性气体腐蚀是造成该井井筒完整性失效的主要因素。     

AHP-SWOT法在道路交通安全改善策略中的应用

针对交通事故的特点,探讨AHP-SWOT方法在道路交通事故评价中的具体应用。SWOT(优势—劣势,机会—威胁)分析法是一种综合考虑系统外部环境和内部条件的各种因素,对其进行系统评价并从中选择最佳策略的方法,但是它缺少定量分析的过程。AHP(层次分析法)具有定性分析和定量分析相结合的优势,采用SWOT和AHP相结合的方法进行评价更加合理和准确。将AHP-SWOT方法应用于道路交通安全评价系统,分析道路交通安全系统所面临的机会和威胁、所处的优势和劣势,可为正确评价道路安全水平、制定合理的道路交通安全改善策略提供理论指导。实例证明该方法可行有效。     

金属矿山安全管理体系的探讨

金属矿山实行安全管理是确保安全生产的重要措施,而合理的安全管理体系是矿山安全管理的根本保障.根据金属矿山生产工艺的特点及危险源的分类,从管理制度、爆破、矿井开采、矿井通风、供电通讯及提升运输6个方面对金属矿山系统建立安全管理体系.该系统将更为直观、全面地为金属矿山系统安全管理提供依据.     

基于风险矩阵和LOPA的风险评价系统在油气管道的应用研究

为规范企业风险管理,在分析国内外各种先进风险管理技术的基础上,对风险矩阵法和保护层分析法(LOPA)进行了优化组合,开发了具有特色的组合风险评价方法,形成了具有鲜明特色的风险评价系统.风险评价系统可实现油气管道系统危害因素的系统识别、多层评价、分级管理、有序控制及监控.该风险评价系统在西部管道公司的长输油气管道系统得到了应用,实践效果表明,该风险评价系统能够规范公司风险管理工作,显著提升公司风险管理水平.     

基于熵权属性识别理论的管道第三方破坏可能性研究

为全面与贴近实际地保证评估结果的准确性,从管道沿线社会环境、居民、企业、地方政府、管道公司5个方面辨识导致第三方破坏发生的影响因素,根据第三方破坏风险评估管段划分原则对管道分段,对各评估指标按百分制赋予分值。根据所评管段各评估指标提供的信息,应用熵权属性识别理论,计算评估指标的权重和属性测度,基于有序分割类和属性识别准则,利用置信度准则综合评估管道发生第三方破坏的可能性。最后,计算出管道第三方破坏可能性的综合评分值。通过算例表明,沿线地方经济发达程度与建设活动,员工自身素质,居民、企业、地方政府同管道公司关系密切程度,管道遭受人为故意破坏时的响应速度的对第三方破坏发生的影响较大。属性识别结果表明,该区段管道发生第三方破坏的可能性偏高,管道公司应对影响因素予以重视和持续地关注。     

基于FUZZY-AHP的危化品管道运输 安全等级综合评判模型与应用

为有效控制与降低危化品管道运输风险,以国家安全生产法和危化品输送管道安全管理规定为基础依据,与我国危化品管道运输现状相结合,建立以危化品管道运输安全等级为目标层的评价指标体系后,基于层次分析法(AHP)理论与模糊数学综合评价法(FUZZY),构建其综合评价模型。通过实例验证表明,该模型对危化品管道运输安全等级的确立科学且有效,所得结论对于提升危化品管道运输安全等级有较好的理论和实践指导作用。     

气藏型地下储气库完整性管理体系及风险识别

为保证气藏型储气库安全运营,保障天然气储配调峰系统的正常运转,对气藏型储气库进行完整性管理及风险识别.明确气藏型地下储气库完整性管理的对象为地面站场系统、储气库井、地质体3大模块,以地质体完整性管理为气藏型储气库完整性管理的特点及难点,并基于管道完整性管理的理念;提出气藏型储气库完整性管理的6步循环:数据采集,单元识别...     

基于模糊层次综合法的加油站现状评价模型及应用

随着社会经济的飞速发展,加油站迅速遍布城乡各地.采用科学、合理的评价方法对加油站的安全现状作出客观的评价以保障其安全生产具有重大意义.建立1种将模糊层次综合评价法应用于加油站安全现状评价的模型,并通过实例论证了该评价模型能有机地将加油站的安全管理因素、设备设施因素、人员因素和环境因素等结合起来,科学、客观地反映出系统现状的安全性和各因素对系统安全性的影响大小,为加油站的安全评价提供了一种有效的综合评价方法,具有一定的实用价值.     

Improvement of integrity management for pressure vessels based on risk assessment - A natural gas separator case study

The process of oil and gas processing plant is complex, the types of pressure vessels are rich, and the functions are critical. However, the working medium is mostly untreated medium, and the hazard factors are complex, which poses a threat to the safe production of oil and gas processing plant. Based on PDCA cycle, this paper establishes a six-step links of integrity management for sustainable improvement of pressure vessels. The typical failure modes of pressure vessels are determined, and the fishbone diagram of risk factors under each failure mode is compiled. Risk quantification and classification of pressure vessels based on failure modes (RBFM) is innovatively proposed. Avoiding incalculable failure frequency index, the process quantification of failure possibility is formed according to the development of hazard factors. A failure consequence calculation model based on the leakage affected area was established. Combined with the failure probability level and risk level, the hierarchical inspection strategy for pressure vessels under different failure modes is established. Finally, the method is applied to the natural gas separator of H processing plant. The research results show that RBFM proposed in this paper can meet the requirements for rapid and accurate risk assessment of pressure vessels in oil and gas processing plant. This paper establishes a safe production barrier for the pressure vessel and improves the intrinsic safety of the equipment.     

国家油气管道地图系统架构探讨

针对我国油气管道管理存在的规划统筹不足、工作衔接不畅、职责履行不力等问题,探讨建设国家油气管道地图系统并分析其架构,以期实现对油气管道的全过程管理。通过问题分析和典型事故案例剖析,明确国家油气管道地图系统的功能定位,确定油气管道全过程管理的5个关键环节;通过统筹分析信息来源和系统预期功能,分析确定系统的部署模式和未来的技术支持方式,提出系统建设标准,明确数据采集信息内容、信息报送方式以及数据变更与更新等核心要素。建立有效联系企业、政府部门和第三方的国家油气管道地图系统,实现对油气管道的全过程管理,对于保障油气管道安全运行具有重要作用。     

基于系统动力学的空管安全绩效预测

为了提高绩效管理的科学性,实现对安全绩效的预测分析,针对空管运行系统的动态性、复杂性和延迟特性,引入系统动力学方法。首先,从管理和结果的角度分析指标间的因果关系,然后在因果图的基础上:1)采用网络层次分析法计算指标权重;2)建立绩效评价的系统动力学模型,由指标权重和评分规则确定指标间的关系方程,进行仿真预测,得到基于指标关系网络的绩效趋势。从查找绩效下降原因和绩效改进措施两方面分析绩效预测的应用,结果表明,运用系统动力学方法分析绩效,不仅可以逆向找到影响绩效的关键指标,还能提前预测决策变化对绩效的影响,保证决策的有效性,提高系统的安全产出。     

基于CREAM的高温熔融金属作业人员可靠性分析

为了对冶金企业高温熔融金属作业人员的可靠性进行评估和量化,基于认知可靠性与失误分析方法(CREAM),提出了适用于高温熔融金属作业的人员可靠性分析方法。该方法给出了通用效能条件(Common Performance Condition, CPC)的评估细则,采用层次分析法(Analytic Hierarchy Process,AHP)与熵值法相结合的CPC因子权重确定方法,利用模糊数学原理实现CPC因子输入的模糊化,从而计算高温熔融金属作业人员失误概率(HEP)和可靠度。通过对炼钢冶炼作业的人员可靠性分析的结果表明:该方法合理有效,具有一定的应用性。