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研究生:吳進喜
研究生(外文):Chin-Shi Wu
論文名稱:石化設備可靠度系統之偵測與其維修技術整合之探討-以C公司媒組工場為例
論文名稱(外文):Discussion on the Detection of System Reliability and Integration of Maintenance Technology for Petrochemical Equipment - A Case Study for Reforming Unit of C Company
指導教授:鄭文魁鄭文魁引用關係盧瑞琴盧瑞琴引用關係
指導教授(外文):Wen-Kueir JehngJui-Chin Lu
學位類別:碩士
校院名稱:國立高雄應用科技大學
系所名稱:工業工程與管理系
學門:工程學門
學類:工業工程學類
論文種類:學術論文
論文出版年:2012
畢業學年度:100
語文別:中文
論文頁數:122
中文關鍵詞:媒組工場以可靠度爲中心的維修維護策略
外文關鍵詞:Reforming UnitReliability-Centered MaintenanceMaintenance Strategy
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現代民生用品均由石化原料製成,人類依賴石化產品日趨緊密,而地球石油蘊含量有限,由於人類不斷地開發抽取,已日漸枯竭,致使原油價格不斷地飛漲,因此石油成為各國爭相儲備的重要物資之一。為了使煉油設備操作順暢且安全無虞,C公司近期引進以可靠度爲中心的維修(Reliability-Centered Maintenance,RCM),研究分析設備故障的原因及影響性,篩選出維護管理績效指標及建立最佳化的維修維護策略。本研究是以C公司所屬媒組工場為對象,期以本研究發展技術及成果提升設備操作之可靠度,延長工場運轉週期、消彌災害發生及降低非預期性停機損失。
在本論文案例分析與探討中,依據C公司媒組工場民國100年間三級責任中心毛利比較表,換算得媒組工場每日產生效益約1450萬台幣,而媒組工場每次開、停爐準備時間為120小時再加上檢修時間,每次非預期性停機的經濟損失將會超過一億台幣。現以RCM分析媒組工場風險分佈並做成日常維修準則,獲致成效如下:
1. 計有13.43%(331項)的中高風險項之設備失效模式,其中36項之經濟影性超過1,950萬台幣。
2. 其中1項高風險失效模式屬於C-6301壓縮機設備,330個中風險失效模式分佈於不同之260個設備中,並得以制定最佳化的維護策略,得以避免失效導致風險的衝擊及提升。
3. 針對較高風險項,總共執行建議1002項維護工作,14種不同工作類型,依不同的工種、頻率以及工作方式來提升媒組工場設備操作的可靠度。
4. 識別出超過48.49%設備項之低風險設備,避免過度維護的狀況。
並透過最佳化維修策略的執行可大幅降低工場的風險,避免非計劃性停爐所導致的巨額經濟損失,並提高工場操作的可靠度及提昇公司營運績效與獲利。
關鍵字:媒組工場、以可靠度爲中心的維修、維護策略。
In the circumstance of now a day of human reliance on petrochemical products is dramatic increasingly, because of livelihood articles are mainly made from petrochemical raw materials. Due to humans continue to excavate which is result with oil in earth contain limited and even depleted. Because of the depletion, oil price has been increasing and also being an important raw material for all countries’ reservation.
In order to ensure all the equipments in refinery being operating smoothly and safely,C Corporation will introduce Reliability-Centered Maintenance( RCM), which is to analyze the factors for abnormal running and influences, in order to select maintenance management achievement goals and build up the optimization maintenance strategy.
For the analysis of this project, the reforming unit of the C Corporation has shown the profit margin approximately NT$ 14,500,000 every day in accordance with three level of responsibility group profit margin comparison table during China Year of 100. For every preparing time of overhaul and start up work which has been taken 120 hours and plus maintenance time, the non- anticipated shut down will be able caused profit loss for over NT$ 100,000,000.
For this article of the case analysis and the discussion, in accordance with the profit margin comparison data for the central of three level reforming workshop which has been shown from month January to September in year 100, the workshop has been gained the profit approximately NT $14,500,000 every day. However, as the workshop start to prepare open running and overhaul planning plus check up time which would be taken 120 hours, For every non-anticipated shut down could be lost over NT$ 100,000,000 .For RCM analysis to reforming unit about the risk distributing over the unit and also the daily maintenance standard has been obtaining the results as below:
1. There will be 36 economic influences that cost over NT$19,500,000,
according to 13.43% (331 items) the high risk item of equipment failure
patterns.
2. There will be one item of high risk expiration pattern belongs to the C-6301
compressor equipment, 330 risk expiration pattern distributes in the different
260 equipments, and can formulate the optimization maintenance strategy and
avoid expiring causes the risk the impact and the promotion.
3. In view of the high risk item, altogether carries out suggested 1002
maintenance works, 14 kinds of different work types, according to the
different kind of work and the frequency as well as to enhance the margin of
safety which the reforming group installation operates.
4. The recognition favorable balance of 48.49% equipments with low risk and
avoid the condition which maintains excessively.
For the optimization service strategy which will be able to reduce the workshop the risk and avoids large amount economic loss with the non-planed shut down, and enhances the workshop operation the margin of safety and the promotion company transport business achievements and the profit.
Keywords: Reforming Unit, Reliability-Centered Maintenance, Maintenance Strategy.
中文摘要............................................................................................................................i
英文摘要..........................................................................................................................iii
誌謝...................................................................................................................................v
目錄..................................................................................................................................vi
表目錄............................................................................................................................viii
圖目錄...............................................................................................................................x
符號說明........................................................................................................................xiv
一、 緒論...........................................................................................................1
1. 1 研究背景與動機.......................................................................................1
1. 2 研究目的...................................................................................................2
1. 3 研究方法...................................................................................................3
1. 4 研究範圍...................................................................................................5
1. 5 研究架構與流程.......................................................................................7
二、 文獻探討...................................................................................................9
2. 1 可靠度領域相關文獻...............................................................................9
2. 2 RCM領域相關文獻...............................................................................18
2. 3 FMEA領域相關文獻..............................................................................21
2. 4 維護策略領域相關文獻.........................................................................23
三、 研究方法.................................................................................................27
3. 1 資料收集.................................................................................................27
3. 1. 1 媒組工場15區進料預餾系統...............................................................30
3. 1. 2 媒組工場20區加氫脫硫系統...............................................................34
3. 1. 3 媒組工場30區重組反應系統...............................................................37
3. 1. 4 媒組工場35區觸媒再生系統...............................................................44
3. 1. 5 媒組工場C-6201壓縮機系統...............................................................48
3. 1. 6 媒組工場C-6301壓縮機系統...............................................................48
3. 1. 7 媒組工場C-6302壓縮機系統...............................................................49
3. 1. 8 媒組工場再生空氣系統.........................................................................50
3. 1. 9 媒組工場高壓配電系統…………………….........................................50
3. 2 RBI風險評估(Risk Based Inspection,RBI).........................................51
3. 2. 1 風險評估相關名詞彙整.........................................................................53
3. 2. 2 風險計算.................................................................................................60
3. 3 失效模式分析、風險接受準則.............................................................61
3. 3. 1 失效機率(POF)的等級...........................................................................61
3. 3. 2 失效後果嚴重性(CoF)...........................................................................62
3. 3. 3 風險矩陣.................................................................................................65
3. 4 失效模式及影響分析.............................................................................66
3. 5 以風險為基準的維護策略 (Risk Based Maintenance,RBM)……....68
3. 6 小結.........................................................................................................71
四、 C公司媒組工場案例之探討..................................................................73
4. 1 RCM相關名詞術語彙整........................................................................73
4. 1. 1 詞彙.........................................................................................................73
4. 1. 2 名詞解釋.................................................................................................74
4. 1. 3 名詞定義.................................................................................................75
4. 2 新增專案.................................................................................................77
4. 3 RCM 失效模式與風險分析..................................................................82
4. 3. 1 失效模式影響分析........................................................……………….85
4. 3. 2 DNV FMEA&風險分析流程.................................................................87
4. 4 失效模式影響分析和風險評估.............................................................89
4. 4. 1 風險評估.................................................................................................90
4. 4. 2 失效模式與影響分析.............................................................................91
4. 5 RCM 失效模式與風險分析結果..........................................................93
4. 6 制定最佳化的維護策略.........................................................................98
4. 6. 1 維護策略制定過程及應用.....................................................................99
4. 6. 2 RCM維護策略最佳化分析結果.........................................................101
4. 7 案例分析與探討...................................................................................104
4. 8 小結.......................................................................................................108
五、 C公司媒組工場執行RCM維修之績效差異分析............................109
六、 結論與建議...........................................................................................114
6. 1 結論.......................................................................................................114
6. 2 建議.......................................................................................................115
參考文獻.......................................................................................................................118




表 目 錄
表 1 往復式泵失效資料庫.............................................................................12
表 2 E-6203A~C的系統風險分析.................................................................15
表 3 E-6201A~I的系統風險分析..................................................................18
表 4 設備維護的歷史.....................................................................................24
表 5 媒組工場設計資料.................................................................................28
表 6 媒組工場15區主要設備編號及名稱...................................................31
表 7 分煉塔再沸加熱系統風險分析.............................................................34
表 8 媒組工場20區主要設備編號及名稱...................................................35
表 9 媒組工場30區主要設備編號及名稱...................................................39
表 10 媒組工場35區主要設備編號及名稱...................................................45
表 11 媒組工場C-6201壓縮機系統區主要設備編號及名稱………….…...48
表 12 媒組工場C-6301壓縮機系統區主要設備編號及名稱…………........48
表 13 媒組工場C-6302壓縮機系統區主要設備編號及名稱.......................49
表 14 媒組工場再生空氣系統區主要設備編號及名稱.................................50
表 15 媒組工場高壓配電系統區主要設備編號及名稱…………….............50
表 16 台塑石化最近一年工安事件表.............................................................52
表 17 材料檢驗及試驗報告表.........................................................................56
表 18 風險等級標誌.........................................................................................61
表 19 失效機率等級基準.................................................................................62
表 20 安全後果等級基準.................................................................................62
表 21 環境後果等級基準.................................................................................63
表 22 經濟後果等級基準.................................................................................64
表 23 維護成本後果等級基準.........................................................................64
表 24 C-6301離心壓縮機系統維護作業週期................................................72
表 25 媒組工場設備類型及項目.....................................................................77
表 26 媒組工場設備類型及數量統計表.........................................................78
表 27 FMEA及高/低風險專案評估表............................................................91
表 28 設備風險與數量統計(以失效模式為基礎)...........................................93
表 29 媒組工場失效模式風險分析表.............................................................94
表 30 高失效費用影響設備之一.....................................................................97
表 31 高失效費用影響設備之二.....................................................................97
表 32 高失效費用影響設備之三.....................................................................98
表 33 高總體風險影響設備.............................................................................98
表 34 檢修工作單完成率統計表(單月).........................................................103
表 35 三級責任中心毛利比較表...................................................................104
表 36 C-6301維修策略..................................................................................105
表 37 F-6301風險分析...................................................................................106
表 38 F-6301維修策略...................................................................................107
表 39 E-6153風險分析...................................................................................108
表 40 E-6153維修策略...................................................................................108
表 41 媒組工場加熱爐失效模式數量及風險分佈.......................................110
表 42 加熱爐維護策略...................................................................................110
表 43 媒組工場壓縮機系統設備分佈...........................................................111
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