设备完整性一页纸Asset Integrity One-Pager · AGI-101 · AgitatorAGI-101 · Agitator

类型Type：AgitatorAgitator · 生成于Generated 2026-08-08 · 数据源：本地 KB（合成/工程估计）Source: local KB (synthetic / engineering estimate)
诚实声明：本页基于种子本体（prior·标准派生）生成，壁厚/材质/可靠性参数为合成或工程估计值，非装置实测；实测数据灌入后该页将自动转为 posterior（实测更新） 态。PMI/ITPM/RCM 结论不替代现场 PMI 实测与正式 FFS 评估。RCM 派生工单（source=KB.derived_rcm）为规则启发式派单，非已验证 JA1011 RCM 分析。Honesty statement: This page is generated from a seed ontology (prior · standard-derived). Wall-thickness / material / reliability parameters are synthetic or engineering estimates, NOT as-found plant measurements; once measured data is ingested the page automatically switches to the posterior (measured-update) state. PMI/ITPM/RCM conclusions do NOT replace field PMI measurement or formal FFS assessment. RCM-derived work orders (source=KB.derived_rcm) are rule-based heuristic dispatches, not validated JA1011 RCM analyses.
高推算est.
关键性等级Criticality Class
3 / 5推算est.
完整性等级 (1-5)Integrity Level (1-5)
14
失效模式 FM 数Failure Modes (FM)
3
高风险 FM (S≥8 或 O≥8)High-risk FM (S≥8 or O≥8)
50
ITPM 工单数ITPM Work Orders
待实测待实测TBD
下次全面检验Next Full Inspection
AI 解读（智能洞察）AI Interpretation (Insight)

本设备共 14 个失效模式（FM），其中 3 个为高风险（S≥8 或 O≥8）。 主导风险来自「机械密封泄漏」（S=9, O=4, AP=中）。 主要失效机理：磨损 / 腐蚀（工艺介质）, 机械疲劳（轴/键）, 机械密封失效。 RCM 维修决策以 CBM 为主（CBM 14 / PM 0 / RTF 0）。 建议优先对高风险 FM 安排 RBI 定点测厚与在线监测复核；含合金部件须执行 PMI 抽检；缺陷按 API 579-1 FFS 闭环。This equipment has 14 failure modes (FM), of which 3 are high-risk (S≥8 or O≥8). The dominant risk is '机械密封泄漏' (S=9, O=4, AP=中). Main failure mechanisms: 磨损 / 腐蚀（工艺介质）, 机械疲劳（轴/键）, 机械密封失效. RCM maintenance decisions are dominated by CBM (CBM 14 / PM 0 / RTF 0). Recommendation: prioritize RBI spot thickness measurement and online-monitoring review for high-risk FMs; perform PMI sampling on alloy components; close defects per API 579-1 FFS.

由结构化 KB 数据合成（compose，非大模型实时推理）；所有结论可在下方章节溯源，参数仍为合成/工程估计。Synthesized from structured KB data (compose, not real-time LLM inference); all conclusions traceable in the sections below; parameters remain synthetic / engineering estimates.

1. 设备台账与 RBI（基于风险检验）1. Equipment Registry & RBI (Risk-Based Inspection)

材质Material不锈钢/碳钢搅拌轴 + 叶轮（接触工艺介质）
介质Service Fluid
设计温度/压力Design T/P— ℃ / — MPa
名义壁厚/最小允许Nominal/Min WT— / — mm
上次检验Last Inspection
损伤机理Damage Mechanisms磨损 / 腐蚀（工艺介质）、机械疲劳（轴/键）、机械密封失效
后果类型Consequence TypeOperational、Environmental
检验有效性Inspection Effectiveness
置信度Confidence0.82
腐蚀速率(估)Corrosion Rate (est.)
壁厚历史趋势（mm）Wall-thickness history trend (mm)
无壁厚历史
适用标准Applicable Standards
API 682 ISO 10441 ISO 21940 ISO 10816-3

2. FMEA 风险画像（AIAG-VDA 2019 AP）2. FMEA Risk Profile (AIAG-VDA 2019 AP)

共 14 个 FM，其中Total {len(fms)} FMs, of which 3 个高风险（S≥8 或 O≥8）are high-risk (S≥8 or O≥8)
FMFMSSOODDAPAP后果Consequence机理Mechanism证据Evidence
机械密封泄漏 ▸ 展开▸ expand944中Safety,Environmental密封面磨损/弹簧失效致介质外泄1
齿轮箱轴承失效 ▸ 展开▸ expand835中Safety,Operational轴承疲劳剥落/润滑不良致齿轮箱失效2
密封冲洗失效 ▸ 展开▸ expand835中Safety,Operational冲洗液中断致密封干磨1
齿轮齿面磨损/点蚀 ▸ 展开▸ expand736中Operational齿面接触疲劳/润滑污染致点蚀1
联轴器失效 ▸ 展开▸ expand735中Safety,Operational弹性元件老化/螺栓松动致联轴器失效1
叶轮不平衡/磨损 ▸ 展开▸ expand645中Operational叶轮结垢/磨损致不平衡1
驱动电机过载/堵转 ▸ 展开▸ expand734低Operational高粘度物料致电机过载堵转1
调速/变频控制失效 ▸ 展开▸ expand734低Operational变频器故障致转速失控2
轴弯曲/偏转 ▸ 展开▸ expand726中Operational悬臂轴受力/热变形致轴弯曲1
润滑失效/油污染 ▸ 展开▸ expand635低Operational润滑油劣化/污染致润滑失效1
振动高（底座松动/不对中） ▸ 展开▸ expand635低Operational地脚松动/不对中致振动超标1
热变形/热应力开裂 ▸ 展开▸ expand727中Safety,Operational温度波动致热应力变形1
电机-齿轮箱-轴不对中 ▸ 展开▸ expand635低Operational对中漂移致附加弯矩1
叶轮紧固件松动 ▸ 展开▸ expand626低Operational锁紧螺母松动致叶轮窜动1

3. PMI 材质验证判定（API RP 578）3. PMI Material Verification (API RP 578)

判定：Decision: 100pct — 合金 + 安全/环境后果 → 100% 材质验证（API RP 578 高后果实践）

4. ITPM 任务库（本设备）4. ITPM Task Library (this equipment)

CBM=27 I=2 PM=21
工单号WO ID类型Type描述Description周期(月)Interval (mo)成本cp(元)Cost cp (¥)成本cf(元)Cost cf (¥)预期风险削减Exp. Risk Reduc.成本来源Cost Source
ITPM-AGI-101-C06CBM状态监测/点检（机械密封泄漏）50001400003.0%prior-template
ITPM-AGI-101-R04CBM基于状态（On-Condition）工单：机械密封泄漏50001400003.0%prior-template
ITPM-AGI-101-C11CBM状态监测/点检（密封冲洗失效）50001400002.0%prior-template
ITPM-AGI-101-R09PM定期弃旧/更换（RTF）工单：密封冲洗失效50001400002.0%prior-template
ITPM-AGI-101-C09CBM状态监测/点检（润滑失效/油污染）50001400002.5%prior-template
ITPM-AGI-101-R07CBM基于状态（On-Condition）工单：润滑失效/油污染50001400002.5%prior-template
ITPM-AGI-101-C07CBM状态监测/点检（叶轮不平衡/磨损）50001400002.5%prior-template
ITPM-AGI-101-R05CBM基于状态（On-Condition）工单：叶轮不平衡/磨损50001400002.5%prior-template
ITPM-AGI-101-C12CBM状态监测/点检（驱动电机过载/堵转）50001400002.0%prior-template
ITPM-AGI-101-R10CBM基于状态（On-Condition）工单：驱动电机过载/堵转50001400002.0%prior-template
ITPM-AGI-101-C03CBM状态监测/点检（齿轮箱轴承失效）50001400002.5%prior-template
ITPM-AGI-101-R01CBM基于状态（On-Condition）工单：齿轮箱轴承失效50001400002.5%prior-template
ITPM-AGI-101-C13CBM状态监测/点检（调速/变频控制失效）50001400002.0%prior-template
ITPM-AGI-101-C16CBM状态监测/点检（电机-齿轮箱-轴不对中）50001400002.0%prior-template
ITPM-AGI-101-R11CBM基于状态（On-Condition）工单：调速/变频控制失效50001400002.0%prior-template
ITPM-AGI-101-R14CBM基于状态（On-Condition）工单：电机-齿轮箱-轴不对中50001400002.0%prior-template
ITPM-AGI-101-C05CBM状态监测/点检（联轴器失效）50001400002.0%prior-template
ITPM-AGI-101-C14CBM状态监测/点检（叶轮紧固件松动）50001400001.5%prior-template
ITPM-AGI-101-R03CBM基于状态（On-Condition）工单：联轴器失效50001400002.0%prior-template
ITPM-AGI-101-R12CBM基于状态（On-Condition）工单：叶轮紧固件松动50001400001.5%prior-template
ITPM-AGI-101-C10CBM状态监测/点检（振动高（底座松动/不对中））50001400002.5%prior-template
ITPM-AGI-101-R08CBM基于状态（On-Condition）工单：振动高（底座松动/不对中）50001400002.5%prior-template
ITPM-AGI-101-C08CBM状态监测/点检（轴弯曲/偏转）50001400001.5%prior-template
ITPM-AGI-101-R06CBM基于状态（On-Condition）工单：轴弯曲/偏转50001400001.5%prior-template
ITPM-AGI-101-C15CBM状态监测/点检（热变形/热应力开裂）50001400001.0%prior-template
ITPM-AGI-101-R13CBM基于状态（On-Condition）工单：热变形/热应力开裂50001400001.0%prior-template
ITPM-AGI-101-C04CBM状态监测/点检（齿轮齿面磨损/点蚀）50001400002.0%prior-template
ITPM-AGI-101-R02CBM基于状态（On-Condition）工单：齿轮齿面磨损/点蚀50001400002.0%prior-template
ITPM-AGI-101-I01IUT 定点测厚240—prior-template
ITPM-AGI-101-I02I表面 MT/PT 探伤（应力集中部位）240—prior-template
ITPM-AGI-101-P17PM齿轮箱油样分析120—prior-template
ITPM-AGI-101-P18PM振动监测120—prior-template
ITPM-AGI-101-P19PM齿面检查120—prior-template
ITPM-AGI-101-P20PM油样分析120—prior-template
ITPM-AGI-101-P21PM联轴器对中检查120—prior-template
ITPM-AGI-101-P22PM螺栓紧固120—prior-template
ITPM-AGI-101-P23PM密封冲洗检查120—prior-template
ITPM-AGI-101-P24PM泄漏监测120—prior-template
ITPM-AGI-101-P25PM动平衡校验120—prior-template
ITPM-AGI-101-P26PM叶轮检查120—prior-template
ITPM-AGI-101-P27PM轴跳动检查120—prior-template
ITPM-AGI-101-P28PM对中120—prior-template
ITPM-AGI-101-P29PM滤油120—prior-template
ITPM-AGI-101-P30PM紧固检查120—prior-template
ITPM-AGI-101-P31PM冲洗管线检查120—prior-template
ITPM-AGI-101-P32PM电流监测120—prior-template
ITPM-AGI-101-P33PM负载检查120—prior-template
ITPM-AGI-101-P34PM控制回路校验120—prior-template
ITPM-AGI-101-P35PM温度梯度监测120—prior-template
ITPM-AGI-101-P36PM激光对中120—prior-template

4.1 处方与成本权衡4.1 Prescription & Cost Trade-off

成本取自 crq 参数（cp=检验成本，cf=失效纠正成本），预期风险削减为不执行该工单的年度失效概率上限近似。当前 crq 未标实测来源，统一标注 prior-template（非装置实测成本）；实测数据经 ingest_measured 审批并入后转 posterior，削减值将升级为风险成本率精算（goal_planning._cost_rate_at）。Costs are drawn from crq parameters (cp = inspection cost, cf = failure correction cost); expected risk reduction approximates the upper bound of annual failure probability if the work order is not executed. Current crq has no measured source, uniformly tagged prior-template (not as-found plant cost); once measured data is approved and ingested via ingest_measured it switches to posterior, and the reduction upgrades to a risk-cost-rate actuarial value (goal_planning._cost_rate_at).

5. RCM 维修决策（策略落地）5. RCM Maintenance Decisions (Strategy Landing)

本设备 14/14 个 FM 已落 RCM 维修决策；分布：14/14 FMs have RCM decisions; distribution: CBM 14 工程推导eng. infer

高风险 FM 的 RCM 维修决策RCM decisions for high-risk FMs
FMFM决策Decision策略Strategy推荐任务Task间隔Interval
齿轮箱轴承失效CBM视情维修(On-Condition)无损检测(UT/MT/PT) 监测裂纹萌生, 关键转动件定时拆检; 振动频谱分析 + 动平衡 + 激光对中, 状态监测趋势管理高风险 1-3 月 / 中风险 6-12 月 / 低风险 检修期 (按 RBI 风险定级)
机械密封泄漏CBM视情维修(On-Condition)泄漏监测 + 密封/填料定期更换, 螺栓热紧固高风险 1-3 月 / 中风险 6-12 月 / 低风险 检修期 (按 RBI 风险定级)
密封冲洗失效CBM视情维修(On-Condition)按压差/效率监测设定清洗周期 + 过滤/防堵维护; 泄漏监测 + 密封/填料定期更换, 螺栓热紧固高风险 1-3 月 / 中风险 6-12 月 / 低风险 检修期 (按 RBI 风险定级)

ITPM 总工单 50 张，RCM 派生 14 张；KB→工单闭环已建立，供 CMMS/SAP 消费。所有决策均属工程推导（非实测台账），执行前须经设备主管确认。Total 50 ITPM work orders, 14 RCM-derived; KB→work-order closed loop established for CMMS/SAP consumption. All decisions are engineering inference (not measured field data), subject to equipment-owner confirmation before execution.

6. 完整性结论与行动6. Integrity Conclusion & Actions

MIQA 状态MIQA Status
完整性等级Integrity LevelNone / 5
上次全面检验Last Full Inspection
下次检验到期Next Inspection Due
MOC 关联MOC Link
建议优先级Recommended Priority

存在 3 个高风险 FM，建议优先安排 RBI 定点测厚与在线监测复核；对含合金部件执行 PMI 抽检。缺陷按 API 579-1 FFS 闭环。There are 3 high-risk FMs; prioritize RBI spot thickness measurement and online-monitoring review; perform PMI sampling on alloy components. Close defects per API 579-1 FFS.