RBI在炼厂催化装置的应用研究
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摘要
随着石油化工装置的大型化和复杂化,装置发生事故所导致的经济损失越来越大,造成的社会影响也越来越恶劣。为了提高设备检验与维护的经济性和科学性,降低事故风险和损失,切实保障石化装置的安全运行,传统的基于时间和条件的检验方法已不再适应,企业迫切需要现代的更加科学有效的设备检验方法。于是自20世纪90年代中期以来,基于风险的检测(RBI)作为一种追求安全性与经济性统一的系统检验理念与方法在西方发达国家石化企业得到广泛应用。通过RBI的实施,可以达到优化检验资源配置,节省设备维修管理费用,提高设备检验有效性的目的。
本文详细地介绍了基于风险的检测技术(RBI)的基本原理及其实施步骤与方法。在工艺危害性分析及定性RBI基础上,采用RB.eye?软件对独山子石化公司催化装置进行了定量RBI分析,并根据RBI分析结果对装置中的设备和管道进行了风险排序。通过定量RBI分析结果,总结分析出了该装置各关键设备和主要管道的主要损伤模式及其腐蚀失效机理。论文还针对不同设备及其不同风险等级制定了相应的检验策略,并且基于RBI分析结果提出了独山子石化公司催化装置设备生产和管理需借鉴的合理化建议,为独山子石化公司催化装置检验计划和长期检修策略的制定提供了较为科学的方法和理论依据。
Along with the increase in the size, complexity, and variety of equipments in petrochemical industry, the loss of resources and its affection in society have been become more serious when an event occurs. In the need of increasingly effective and scientific inspection of equipments in petroleum-chemical engineering, ensure the serucity of petrochemiacal works and decrease the loss deriving from disabled facilities, the old methods of time-based inspections and even condition-based inspections are no longer availability to reduce the frequency of occurrence of event, it has already been strongly concerned about how to apply modern science and technology of security. So the risk-based inspection (RBI) as a concept and methodology for system inspection seeks for unification of safety and economy has been wide application in petrochemical enterprises of Europe and America since middle 1990s. Implementing RBI can achieve optimize the allocation of inspection resource, saving the expenditure of maintaining and managing of equipments, at the same time ensure the effective of the inspection.
In this paper, the basic theory of risk-based inspection (RBI) technology and its actualizing steps and methods is introduced in detail. And then RB.eye? software is adapted to conduct quantitative RBI analysis on Catalytic units of DuShanZi Petrochemical Company based on process hazard analysis and qualitative RBI, and risk prioritization is carried out for equipments and pipelines on the plant according to RBI results. Through the results of quantitative RBI analysis, major damage mode and corrosive mechanism are identified for the plant critical equipments and major pipelines one by one. In this paper, the inspection program which offers scientific basis for inspection schedule and strategy was made according to different equipment, piping and different risk classes. And based on analysis of RBI, several useful advices of production and management are proposed, its provide scientific methods and theory gist for establishment of inspection schedule and inspection strategy extended on Catalytic units of DuShanZi Petrochemical Company.
本文详细地介绍了基于风险的检测技术(RBI)的基本原理及其实施步骤与方法。在工艺危害性分析及定性RBI基础上,采用RB.eye?软件对独山子石化公司催化装置进行了定量RBI分析,并根据RBI分析结果对装置中的设备和管道进行了风险排序。通过定量RBI分析结果,总结分析出了该装置各关键设备和主要管道的主要损伤模式及其腐蚀失效机理。论文还针对不同设备及其不同风险等级制定了相应的检验策略,并且基于RBI分析结果提出了独山子石化公司催化装置设备生产和管理需借鉴的合理化建议,为独山子石化公司催化装置检验计划和长期检修策略的制定提供了较为科学的方法和理论依据。
Along with the increase in the size, complexity, and variety of equipments in petrochemical industry, the loss of resources and its affection in society have been become more serious when an event occurs. In the need of increasingly effective and scientific inspection of equipments in petroleum-chemical engineering, ensure the serucity of petrochemiacal works and decrease the loss deriving from disabled facilities, the old methods of time-based inspections and even condition-based inspections are no longer availability to reduce the frequency of occurrence of event, it has already been strongly concerned about how to apply modern science and technology of security. So the risk-based inspection (RBI) as a concept and methodology for system inspection seeks for unification of safety and economy has been wide application in petrochemical enterprises of Europe and America since middle 1990s. Implementing RBI can achieve optimize the allocation of inspection resource, saving the expenditure of maintaining and managing of equipments, at the same time ensure the effective of the inspection.
In this paper, the basic theory of risk-based inspection (RBI) technology and its actualizing steps and methods is introduced in detail. And then RB.eye? software is adapted to conduct quantitative RBI analysis on Catalytic units of DuShanZi Petrochemical Company based on process hazard analysis and qualitative RBI, and risk prioritization is carried out for equipments and pipelines on the plant according to RBI results. Through the results of quantitative RBI analysis, major damage mode and corrosive mechanism are identified for the plant critical equipments and major pipelines one by one. In this paper, the inspection program which offers scientific basis for inspection schedule and strategy was made according to different equipment, piping and different risk classes. And based on analysis of RBI, several useful advices of production and management are proposed, its provide scientific methods and theory gist for establishment of inspection schedule and inspection strategy extended on Catalytic units of DuShanZi Petrochemical Company.
引文
[1] American Petroleum Institute,Risk-Based Inspection Base Resource Document,API580,first Edition,2002,5
[2]王鲁荣,RBI在石化装置检测流程中的应用研究:[硕士学位论文],天津;天津大学,2006
[3] American Petroleum Institute,Risk-Based Inspection Base Resource Document,API581,first Edition,2000,5
[4]戴树和,“风险分析技术(一)风险分析的原理和方法”,压力容器,2002,19(2):1～9
[5]李亚红,乙烯装置基于风险的检验(RBI)方法应用:[硕士学位论文],天津;天津大学,2006
[6]中华人民共和国国家质量监督检验检疫总局,TSG R7001-2004,压力容器定期检验规则,北京:中国标准出版社,2004-06-23
[7]王志坤,石化工业基于风险的设备检测管理研究:[硕士学位论文],天津;天津大学,2006
[8]合肥机械通用研究所压力容器检验站,中国石油天然气股份有限公司独山子石化分公司炼油厂I催化裂化装置风险评估(RBI)报告,2006,12
[9]陈刚,左尚志,陶雪荣等,“承压设备的风险评估技术及其在我国的应用和发展趋势”,中国安全生产科学技术,2005,1(1):31～35
[10]陆东,牟善军“欧洲设备风险检查技术及应用概况”,HSE,2004,4(1):36～39
[11]顾望平,“风险检验技术在茂明石化的应用”,HSE,2004,4(8):36～38
[12]杨林娟,沈士明,“工业风险分析与评价方法综述二”,压力容器,2005,22(8):35～39
[13]杨林娟,沈士明,“工业风险分析与评价方法综述一”,压力容器,2005,22(7):45～49
[14]张秀敏,赵建平,“化工装置风险定量评估方法”,石油化工设备,2005,34(2):29～31
[15]徐培德,刘明亮,董献洲,“基于PRA方法的风险分析系统设计”,武汉理工大学学报,2003,25(3):134～140
[16]金承尧,赵建平,“基于RBI方法的在役安全阀风险评价技术研究”,南京工业大学学报,2004,26(5):25～29
[16]杨铁成,陈学东,魏安安等,“基于半定量风险分析的加氢装置安全评估”,压力容器,2002,19(12):43～45
[17]陈学东,杨铁成,艾志斌等,“基于风险的检测(RBI)在实践中若干问题的讨论”,压力容器,2005,22(7):36～44
[18]陈学东,王冰,杨铁成等,“基于风险的检测(RBI)在中国石化企业的实践及若干问题讨论”,压力容器,2004,21(8):39～45
[19]张鹏,陈利琼,侯向秦等,“基于风险的油气管道最优完整性维护决策”,天然气工业,2004,24(9):159～162
[20]朱瑞松,“应用RBI开展高压加氢裂化装置风险检验”,压力容器,2005,22(5):45～49
[21]黄贤滨,李延渊,兰正贵,“新一代设备管理技术-基于风险的检验”,物资装备管理,2004,22(3):73～77
[22]翟文华,“DNV安全评价软件进行定量风险评估的应用”,石油化工安全技术,2002,18(3):6～11
[23] American Petroleum Institute,Pressure Vessel Inspection Code:Maintenance Inspection,Rating,Repair,and Alteration,API510,first Edition,2000,12
[24] American Petroleum Institute,Piping Inspection Code: Inspection, Repair, Alteration ,and Rerating of In-Service Piping System,,API570,Second Edition,2000,12
[25] American Petroleum Institute,Damage Mechanisms Affecting Fixed Equipment in the Refining Industry,API571,first Edition,2003,12
[26] American Petroleum Institute,A Study of Corrosion in Hydaroprocess Reactor Effluent Air Cooler Systems,API932,first Edition,2002,12
[2]王鲁荣,RBI在石化装置检测流程中的应用研究:[硕士学位论文],天津;天津大学,2006
[3] American Petroleum Institute,Risk-Based Inspection Base Resource Document,API581,first Edition,2000,5
[4]戴树和,“风险分析技术(一)风险分析的原理和方法”,压力容器,2002,19(2):1～9
[5]李亚红,乙烯装置基于风险的检验(RBI)方法应用:[硕士学位论文],天津;天津大学,2006
[6]中华人民共和国国家质量监督检验检疫总局,TSG R7001-2004,压力容器定期检验规则,北京:中国标准出版社,2004-06-23
[7]王志坤,石化工业基于风险的设备检测管理研究:[硕士学位论文],天津;天津大学,2006
[8]合肥机械通用研究所压力容器检验站,中国石油天然气股份有限公司独山子石化分公司炼油厂I催化裂化装置风险评估(RBI)报告,2006,12
[9]陈刚,左尚志,陶雪荣等,“承压设备的风险评估技术及其在我国的应用和发展趋势”,中国安全生产科学技术,2005,1(1):31～35
[10]陆东,牟善军“欧洲设备风险检查技术及应用概况”,HSE,2004,4(1):36～39
[11]顾望平,“风险检验技术在茂明石化的应用”,HSE,2004,4(8):36～38
[12]杨林娟,沈士明,“工业风险分析与评价方法综述二”,压力容器,2005,22(8):35～39
[13]杨林娟,沈士明,“工业风险分析与评价方法综述一”,压力容器,2005,22(7):45～49
[14]张秀敏,赵建平,“化工装置风险定量评估方法”,石油化工设备,2005,34(2):29～31
[15]徐培德,刘明亮,董献洲,“基于PRA方法的风险分析系统设计”,武汉理工大学学报,2003,25(3):134～140
[16]金承尧,赵建平,“基于RBI方法的在役安全阀风险评价技术研究”,南京工业大学学报,2004,26(5):25～29
[16]杨铁成,陈学东,魏安安等,“基于半定量风险分析的加氢装置安全评估”,压力容器,2002,19(12):43～45
[17]陈学东,杨铁成,艾志斌等,“基于风险的检测(RBI)在实践中若干问题的讨论”,压力容器,2005,22(7):36～44
[18]陈学东,王冰,杨铁成等,“基于风险的检测(RBI)在中国石化企业的实践及若干问题讨论”,压力容器,2004,21(8):39～45
[19]张鹏,陈利琼,侯向秦等,“基于风险的油气管道最优完整性维护决策”,天然气工业,2004,24(9):159～162
[20]朱瑞松,“应用RBI开展高压加氢裂化装置风险检验”,压力容器,2005,22(5):45～49
[21]黄贤滨,李延渊,兰正贵,“新一代设备管理技术-基于风险的检验”,物资装备管理,2004,22(3):73～77
[22]翟文华,“DNV安全评价软件进行定量风险评估的应用”,石油化工安全技术,2002,18(3):6～11
[23] American Petroleum Institute,Pressure Vessel Inspection Code:Maintenance Inspection,Rating,Repair,and Alteration,API510,first Edition,2000,12
[24] American Petroleum Institute,Piping Inspection Code: Inspection, Repair, Alteration ,and Rerating of In-Service Piping System,,API570,Second Edition,2000,12
[25] American Petroleum Institute,Damage Mechanisms Affecting Fixed Equipment in the Refining Industry,API571,first Edition,2003,12
[26] American Petroleum Institute,A Study of Corrosion in Hydaroprocess Reactor Effluent Air Cooler Systems,API932,first Edition,2002,12
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