设备完整性一页纸Asset Integrity One-Pager · CV-201A · 控制阀CV-201A · Control Valve

类型Type：控制阀Control Valve · 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.
A
关键性等级Criticality Class
2
完整性等级 (1-5)Integrity Level (1-5)
14
失效模式 FM 数Failure Modes (FM)
5
高风险 FM (S≥8 或 O≥8)High-risk FM (S≥8 or O≥8)
65
ITPM 工单数ITPM Work Orders
2027-09
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 5 个为高风险（S≥8 或 O≥8）。 主导风险来自「线圈烧毁」（S=9, O=3, AP=中）。 主要失效机理：均匀腐蚀/氧化, 冲蚀/磨损, 疲劳。 RCM 维修决策以 CBM 为主（CBM 8 / PM 2 / RTF 4）。 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 5 are high-risk (S≥8 or O≥8). The dominant risk is '线圈烧毁' (S=9, O=3, AP=中). Main failure mechanisms: 均匀腐蚀/氧化, 冲蚀/磨损, 疲劳. RCM maintenance decisions are dominated by CBM (CBM 8 / PM 2 / RTF 4). 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/碳钢阀体
介质Service Fluid工艺介质
设计温度/压力Design T/P80 ℃ / 4.0 MPa
名义壁厚/最小允许Nominal/Min WT10.0 / 7.0 mm
上次检验Last Inspection2025-09
损伤机理Damage Mechanisms均匀腐蚀/氧化、冲蚀/磨损、疲劳
后果类型Consequence TypeOperational
检验有效性Inspection Effectiveness0.82
置信度Confidence0.78
腐蚀速率(估)Corrosion Rate (est.)0.210 mm/yr
壁厚历史趋势（mm）Wall-thickness history trend (mm)
7.06.8
适用标准Applicable Standards
API 581-2025 API 580 API 571 API 579-1/ASME FFS-1 GB/T 44692 GB/T 21109

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 5 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
阀体腐蚀/冲蚀 ▸ 展开▸ expand843中Safety—2
弹簧疲劳/断裂 ▸ 展开▸ expand844中Operational—2
线圈烧毁 ▸ 展开▸ expand932中Operational—2
阀芯卡涩→不动作 ▸ 展开▸ expand844中Operational—2
膜片破裂 ▸ 展开▸ expand833低Operational—2
减压阀漂移 ▸ 展开▸ expand564中Operational—2
阀座表面损伤→内漏 ▸ 展开▸ expand734低Operational—2
阀芯冲蚀 ▸ 展开▸ expand733低Operational—2
阀杆卡涩/弯曲 ▸ 展开▸ expand644中Operational—2
I/P转换器故障 ▸ 展开▸ expand732低Operational—2
触点腐蚀/接触不良 ▸ 展开▸ expand643中Operational—2
滤芯堵塞→供气不足 ▸ 展开▸ expand733低Operational—2
填料磨损→外漏 ▸ 展开▸ expand543中Operational—2
反馈杆松动 ▸ 展开▸ expand533低Operational—2

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

判定：Decision: sampling_10pct — 合金 + 一般后果 → 抽检 10%（最少 1 件），API RP 578 §5

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

CBM=19 I=3 PM=43
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-CV-201A-C13CBM状态监测/点检（线圈烧毁）1960506008.9%prior-template
ITPM-CV-201A-R04CBM基于状态（On-Condition）工单（派生）：线圈烧毁1960506008.9%prior-template
ITPM-CV-201A-C08CBM状态监测/点检（填料磨损→外漏）1960330008.9%prior-template
ITPM-CV-201A-C12CBM状态监测/点检（反馈杆松动）1960330008.9%prior-template
ITPM-CV-201A-C14CBM状态监测/点检（阀芯卡涩→不动作）19604620010.7%prior-template
ITPM-CV-201A-R05CBM基于状态（On-Condition）工单（派生）：阀芯卡涩→不动作19604620010.7%prior-template
ITPM-CV-201A-C09CBM状态监测/点检（膜片破裂）1960462008.9%prior-template
ITPM-CV-201A-R02CBM基于状态（On-Condition）工单（派生）：膜片破裂1960462008.9%prior-template
ITPM-CV-201A-C11CBM状态监测/点检（I/P转换器故障）1960418008.9%prior-template
ITPM-CV-201A-C16CBM状态监测/点检（滤芯堵塞→供气不足）1960418008.9%prior-template
ITPM-CV-201A-C06CBM状态监测/点检（阀芯冲蚀）1960418008.9%prior-template
ITPM-CV-201A-C15CBM状态监测/点检（触点腐蚀/接触不良）19603740010.7%prior-template
ITPM-CV-201A-C07CBM状态监测/点检（阀杆卡涩/弯曲）19603740010.7%prior-template
ITPM-CV-201A-C10CBM状态监测/点检（弹簧疲劳/断裂）1960462008.9%prior-template
ITPM-CV-201A-R03CBM基于状态（On-Condition）工单（派生）：弹簧疲劳/断裂1960462008.9%prior-template
ITPM-CV-201A-C04CBM状态监测/点检（阀体腐蚀/冲蚀）196015840010.7%prior-template
ITPM-CV-201A-R01CBM基于状态（On-Condition）工单（派生）：阀体腐蚀/冲蚀196015840010.7%prior-template
ITPM-CV-201A-C05CBM状态监测/点检（阀座表面损伤→内漏）1960418008.9%prior-template
ITPM-CV-201A-C17CBM状态监测/点检（减压阀漂移）19603300012.5%prior-template
ITPM-CV-201A-I01IUT 测厚网格扫查240—prior-template
ITPM-CV-201A-I02IUT 定点测厚240—prior-template
ITPM-CV-201A-I03I表面 MT/PT 探伤（应力集中部位）240—prior-template
ITPM-CV-201A-P18PM每3个月超声波测厚120—prior-template
ITPM-CV-201A-P19PM每月目视检查腐蚀坑120—prior-template
ITPM-CV-201A-P20PM每年压力测试120—prior-template
ITPM-CV-201A-P21PM建立SIL评估（按IEC 61511）确定安全完整性等级120—prior-template
ITPM-CV-201A-P22PM每1个月执行proof test验证保护层有效性120—prior-template
ITPM-CV-201A-P23PM每月关闭阀门后监测下游压力上升120—prior-template
ITPM-CV-201A-P24PM每季度声发射检测泄漏120—prior-template
ITPM-CV-201A-P25PM每年检查密封面120—prior-template
ITPM-CV-201A-P26PM每月检查阀芯外观（通过拆检或内窥镜）120—prior-template
ITPM-CV-201A-P27PM每日监测流量或压降异常120—prior-template
ITPM-CV-201A-P28PM每周手动操作感受阻力120—prior-template
ITPM-CV-201A-P29PM每月检查阀杆直线度120—prior-template
ITPM-CV-201A-P30PM每季度检查执行机构行程120—prior-template
ITPM-CV-201A-P31PM每月目视检查阀杆处有无泄漏120—prior-template
ITPM-CV-201A-P32PM每3个月调整填料压盖120—prior-template
ITPM-CV-201A-P33PM每2年更换填料120—prior-template
ITPM-CV-201A-P34PM每月检查执行机构动作是否正常120—prior-template
ITPM-CV-201A-P35PM每季度进行气密性测试120—prior-template
ITPM-CV-201A-P36PM每3年更换膜片120—prior-template
ITPM-CV-201A-P37PM每月检查弹簧外观有无裂纹或变形120—prior-template
ITPM-CV-201A-P38PM每半年测量弹簧刚度变化120—prior-template
ITPM-CV-201A-P39PM每5年更换弹簧120—prior-template
ITPM-CV-201A-P40PM每月检查输出气压与输入电流对应关系120—prior-template
ITPM-CV-201A-P41PM每季度使用诊断工具检测响应120—prior-template
ITPM-CV-201A-P42PM每日观察阀门定位精度变化120—prior-template
ITPM-CV-201A-P43PM每月检查反馈杆紧固螺栓120—prior-template
ITPM-CV-201A-P44PM每周观察阀门行程与指令信号偏差120—prior-template
ITPM-CV-201A-P45PM每季度使用振动监测120—prior-template
ITPM-CV-201A-P46PM每月测量线圈电阻值120—prior-template
ITPM-CV-201A-P47PM每周检查线圈表面有无焦痕120—prior-template
ITPM-CV-201A-P48PM每日监测电磁阀动作电流120—prior-template
ITPM-CV-201A-P49PM每周进行电磁阀动作测试120—prior-template
ITPM-CV-201A-P50PM每日检查气源过滤质量120—prior-template
ITPM-CV-201A-P51PM每月监测电磁阀动作时间120—prior-template
ITPM-CV-201A-P52PM每3个月测量触点接触电阻，记录趋势120—prior-template
ITPM-CV-201A-P53PM每6个月检查触点外观，清洁氧化层120—prior-template
ITPM-CV-201A-P54PM当接触电阻超过初始值20%时更换限位开关120—prior-template
ITPM-CV-201A-P55PM每1个月检查滤芯压差指示器，记录压差120—prior-template
ITPM-CV-201A-P56PM每3个月更换滤芯，使用原厂备件120—prior-template
ITPM-CV-201A-P57PM安装气源净化装置，定期排放冷凝水120—prior-template
ITPM-CV-201A-P58PM每6个月校验输出压力，调整至设定值±5%120—prior-template
ITPM-CV-201A-P59PM每12个月更换膜片和弹簧组件120—prior-template
ITPM-CV-201A-P60PM每次校验后锁紧调节螺钉并加标记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 8 RTF 4 PM 2 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
阀体腐蚀/冲蚀RTF设计改进/探测任务(Redesign)壁厚/型线超声测厚 + 耐磨层状态检查, 视情修复或涂层; 材质复检 + 无损检测 + 设计/材质升级整改(RTF); 无损检测(UT/VT/MT/PT), 按 API 581 RBI 风险定级设定检验间隔; 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)
膜片破裂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高风险 1-3 月 / 中风险 6-12 月 / 低风险 检修期 (按 RBI 风险定级)
弹簧疲劳/断裂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; 沉降/变形观测 + 支撑/基础评估; 无损检测(UT/VT/MT/PT), 按 API 581 RBI 风险定级设定检验间隔高风险 1-3 月 / 中风险 6-12 月 / 低风险 检修期 (按 RBI 风险定级)
线圈烧毁PM主动维修(Scheduled)绝缘/电气试验 + 继电保护定值校核 + 操动机构特性测试; 温度/红外热成像监测, 超温报警与根因排查高风险 1-3 月 / 中风险 6-12 月 / 低风险 检修期 (按 RBI 风险定级)
阀芯卡涩→不动作PM主动维修(Scheduled)功能测试/标定/校验, 按厂家与 SIL 要求周期执行高风险 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 65 张，RCM 派生 0 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 65 ITPM work orders, 0 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 Statusin_service
完整性等级Integrity Level2 / 5
上次全面检验Last Full Inspection2025-09
下次检验到期Next Inspection Due2027-09
MOC 关联MOC LinkMOC-OPC-CV-201A
建议优先级Recommended Priority

存在 5 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 5 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.