A Study on the Integration of MI and RBI into Maintenance Management Systems

[[abstract]]長期以來製程工廠在安全維護上，重點多放在壓力容器等設備的本體上，檢查規劃與執行亦然。不過，經驗顯示，事故通常發生在系統最脆弱的部位，而這些部位通常不是設備本體。因此，近年各國檢查規範開始接受並導入系統性檢查的觀念。然而，在執行實務上，因系統性檢查之項目、數量、方法、週期和判定標準等有待建立準則，要落實並不容易，且各國因檢查機構與權限的設定因國情與文化不同，而有顯著的差別，例如美國給予授權檢查員很大的裁量權來決定檢查結果，日本與我國則比較重視專責機構的運作，故為提升製程工廠安全防護，導入系統安全檢查機制，有必要進行設備維護管理、設備完整性與風險基檢查結合機制與技術之探討。 本報告以美國 OSHA PSM 之 MI 項目及日本保安檢查為輔，從業界之設備完整性現況調查為起點。一方面研究產業的維修管理模式，另一方面以國內石化業的設備管理模式為基準，對設備分類與分級作法開始整理，並針對常用的失效分析技術如失效模式與效應分析(FMEA)及風險基礎檢查(RBI)等，整理評估方法，並建立應用案例。最後，調查石化業常用的維修管理系統(CMMS)，發展適合我國業者導入的設備完整性作法，最後將成果以實務手冊呈現。研究建議石化相關公會、協會及學術界，有系統引進國外如 API 相關標準、技術等技術規範，政府支援辦理相關課程、研討會及技術說明會等，並在監督檢查上建立系統性檢查機制，從方法與制度上建立落實誘因，促進雇主一起參與執行。另建議事業單位於平時即進行相關之數據資料蒐集，並完整確實保存與分析，不但能強化設備之安全管理，對於往後之設備相關檢查作業透過數據管理，亦更有說服力。[[abstract]]Pressure vessels have long been the focus of safety maintenance in manufacturing plants, and inspection regulations also focus on pressure vessels and their components. Experience shows, however, that accidents frequently occur at the weakest points in a system, and that these points are often in piping, tubes, and other locations. The recent trend in inspection planning has been moving toward the concept of systemic inspection, with increased emphasis on overall plant safety. What makes systemic inspection difficult is that it is not easy to determine the number of inspections to be made, let alone the methods of inspection, number of check points, and judgment criteria. Inspection agencies and the extent of their authority vary among different countries. In the United States, for example, authorized inspectors have a great amount of discretionary power over the inspection and certification process. In Japan and Taiwan, by contrast, the inspection process is controlled largely by the authorized inspection agencies. Also in Taiwan, industries want the items and extent of inspection to be as thorough and clearly defined as possible. Using the Mechanical Integrity (MI)-related items in the Process Safety Management (PSM) system of America’s OSHA as a platform, we set out to gather technical information and data on Japanese safety inspection regulations as well as from other sources. We started with sample plant investigations aimed at gaining an understanding of how industry establishes MI regulations and at comparing maintenance management systems. At the same time, we studied several useful technologies and practices. Computerization-related tasks included equipment classification, ranking, and damage coding. Failure analysis methodologies have long been difficult for plant engineers to handle, so in this report we provide a concise introduction to and implementation procedures for failure mode and effect analysis (FMEA) and risk based inspection (RBI), together with sample problems. Key functionalities of computerized maintenance management systems (CMMS) that are necessary for the assurance of mechanical integrity are also addressed. Finally, the overall results were compiled and presented in a handbook of guidelines. Topics covered in the study included: A comparison of pressure vessel regulations in America, Japan, and Taiwan; A summary of maintenance management practices of typical petrochemical plants in Taiwan; Application of CMMS; Introduction to failure and risk analysis of processing equipment; and Investigation of maintenance practices of five sample chemical plants