Application of Risk-Based Inspection and Effects of Crucial Parameters to Petrochemical Industry

[[abstract]] 過去石化廠的設備管理模式，往往是以維修導向、被動的進行，也就是設備發生故障、洩漏時才投入檢修。因應國際發展趨勢與製程特性多元化的發展，功能導向的法條還散見幾個法規中。法規對列管的事業單位要求事項包含對製程中的設備、管線以及閥件與控制系統等皆要定期檢討檢查及測試頻率，與過去相比，列管對象增加且執行方式更有彈性。 API 581所揭序的風險基礎檢查技術是以設備洩漏風險做為制訂與管理工廠檢測計畫依據的方法。RBI以全定量模式來安排檢測計畫，其分析過程需要大量的製程、檢查、維修與管理資訊及正確參數，其中隱含的意涵是，這將拉大有效導入風險基準檢查(Risk-Based Inspection RBI)企業與其他企業的差距。反觀國內石化產業，由於長期不重視數據資料管理與記錄保存，以致在嘗試導入時遇到很大的難題。 國內石化產業在導入RBI時，因為資料保存不佳，使得評估往往遇到困難。本研究將試著找出幾個評估過程中對風險有較大影響幾個參數，並藉由計算範例展示風險計算的流程，整合評估所需的各項參數。配合國內法規走向，展示RBI如何運用至檢測規劃上；最後以excel-based程式進行案例分析。 RBI最終是要替雇主規劃出最佳的檢查方法和頻率，其概念完全符合PDCA的精神。若能確實將RBI的技術導入業界，對於設備的延長替代方案、設備的風險預知定能有極大的幫助。執行上除了考驗公司內部資訊管理能力外，更重要的是需要專業知識與現場經驗的配合。從RBI分析角度發現資產管理系統應加強上下連結功能，使建造及歷史紀錄與現況連結，得以運用檢查數據趨勢性的分析，最終可掌握設備剩餘壽命，進而制訂汰換計畫，達成企業永續營運的目的。[[abstract]] The conventional equipment management philosophy in petro-chemical plants is passive and repair-oriented that is maintenance is only initiated when breakdowns and/or leakages are found Gradually even government regulations mandate inspection on some of the pressure equipment and piping Also equipment related international standards move even further to suggest performance based practices The most recent equipment codes require piping controls and pressure equipment to all be inspected periodically The Risk-based inspection(RBI) technology as described in API 581 focus largely on the risk of chemical leakage from process equipment and piping With knowledge of the potential risk one can then plan and schedule inspections in order to reduce or mitigate risk due to leakage In order to perform RBI quantitatively numerous historical data from process inspection repair as well as plant management are required And it has almost become an industrial standard for a petro-chemical plant to perform RBI which on the other hand makes others in chase further behind As for most of the domestic chemical plants plant operation and maintenance data was never well preserved and utilized Without quality data RBI analysis will be very difficult In this study all the parameters required for RBI analysis is gathered with which we can investigate how each parameter affects risk in calculation An Excel-based RBI program has been created in order to demonstrate the process When properly implemented the RBI is realized through a well-tuned and optimized inspection plan which is totally PDCA-conformed To those who seeking a permit to extend required inspection interval of pressure equipment RBI is so far the most widely accepted methodology Integrating RBI with plant asset management system the whole life cycle data of plant asset should be well documented and analyzed so that the plant can know remaining life of each critical equipment when one should be replaced without putting the whole manufacturing in jeopard