工場大修設備和管線檢查規劃研究與應用實務

本研究主要導入風險基準檢查理念來進行工場大修設備和管線檢查重點規劃，主要開發和應用的技術包括劣化模式分析、腐蝕環路(Corrosion Circuit)規劃、風險分級模式建立和檢查重點規劃方法，結果並實際應用至現場大修檢查工作中，於大修過程中對所發現的腐蝕劣化問題進行原因診斷和改善、研擬最適化檢修和銲補方案，本文以實例來說明整個技術的應用過程以及成效，最後提出完整性的強化要項以及經驗檢討。研究結果和現場應用說明如下： 1.本研究導入風險基準檢查技術進行工場大修前設備和管線檢查規劃，由實際應用案例顯示大修前經由有系統化檢查重點規劃，大修期間落實和有效檢查，已發現多件設備和管線瀕臨洩漏之腐蝕劣化問題，並對發現的腐蝕劣化問題肇因進行診斷和改善，同時研擬可靠的銲補方案，據此進行預防檢修工作，達到設備和管線預知和預防保養的目的，可有效避免因洩漏所引起之工安和環保問題以及降低非計劃性停爐和延宕大修時程所導致的經濟性損失。 2.經由檢討和分析過去執行大修檢查規劃經驗以及腐蝕劣化洩漏成因，從設計／建造、檢查、維修和管理等方面提出完整性強化方案以及經驗檢討，詳見第四和五章節討論。

關鍵字

大修規劃；檢查；維修

並列摘要

This Study mainly inducts the risk-based inspection method to carry on inspection planning of refinery equipment and piping during turnaround. The combined approach was developed including damage model, corrosion circuit, risk ranking and planning method. The results were practically applied in turnaround inspection. The root cause of corrosion damage was identified and the program of maintenance activities was implemented during turnaround. Finally, execution experience and the important items strengthening equipment integrity were proposed. The findings and the field application were revealed in the followings: 1. Risk based inspection was applied in turnaround inspection planning and activities. The efforts reveal that implementing systemic inspection plan and effective inspection can find the corrosion damage events on the verge of leakage. A reliable repair program was developed by diagnosing the root cause of corrosion damage to conduct the preventive maintenance. The cost due to leakage events, unplanning shutdown and turnaround schedule delay could be reduced. 2. According to the execution experience of over twenty inspection plan cases, experience learning and the strengthening items of equipment integrity were proposed from the design, fabrication, maintenance and management viewpoint.

並列關鍵字

Inspection Planning ； Inspection ； Maintenance

國際替代計量

工場大修設備和管線檢查規劃研究與應用實務

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