本设备共 11 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「酸露点腐蚀」（S=9, O=4, AP=中）。 主要失效机理：均匀腐蚀/氧化, 冲蚀/磨损。 RCM 维修决策以 CBM 为主（CBM 9 / PM 0 / RTF 2）。 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 11 failure modes (FM), of which 3 are high-risk (S≥8 or O≥8). The dominant risk is '酸露点腐蚀' (S=9, O=4, AP=中). Main failure mechanisms: 均匀腐蚀/氧化, 冲蚀/磨损. RCM maintenance decisions are dominated by CBM (CBM 9 / PM 0 / RTF 2). 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.
| 材质Material | 碳钢/衬里 |
| 介质Service Fluid | 工艺气/急冷液 |
| 设计温度/压力Design T/P | 90 ℃ / 0.1 MPa |
| 名义壁厚/最小允许Nominal/Min WT | 16.0 / 12.0 mm |
| 上次检验Last Inspection | 2025-09 |
| 损伤机理Damage Mechanisms | 均匀腐蚀/氧化、冲蚀/磨损 |
| 后果类型Consequence Type | Operational |
| 检验有效性Inspection Effectiveness | 0.82 |
| 置信度Confidence | 0.78 |
| 腐蚀速率(估)Corrosion Rate (est.) | 0.360 mm/yr |
| FMFM | SS | OO | DD | APAP | 后果Consequence | 机理Mechanism | 证据Evidence |
|---|---|---|---|---|---|---|---|
| 酸露点腐蚀 ▸ 展开▸ expand | 9 | 4 | 3 | 中 | Operational | — | 1 |
| 管束腐蚀泄漏 ▸ 展开▸ expand | 9 | 4 | 3 | 中 | Safety | — | 1 |
| 泵汽蚀 ▸ 展开▸ expand | 8 | 4 | 3 | 中 | Operational | — | 1 |
| 结垢→换热下降 ▸ 展开▸ expand | 6 | 6 | 3 | 中 | Operational | — | 1 |
| 液位计堵塞→溢流/抽空 ▸ 展开▸ expand | 7 | 5 | 3 | 中 | Operational | — | 1 |
| 衬里脱落 ▸ 展开▸ expand | 7 | 4 | 3 | 中 | Operational | — | 1 |
| 喷嘴堵塞 ▸ 展开▸ expand | 6 | 5 | 3 | 中 | Operational | — | 1 |
| 机械密封泄漏 ▸ 展开▸ expand | 7 | 4 | 4 | 中 | Safety | — | 1 |
| 喷嘴腐蚀→雾化不良 ▸ 展开▸ expand | 5 | 5 | 3 | 中 | Operational | — | 1 |
| 填料堵塞/结垢 ▸ 展开▸ expand | 6 | 4 | 3 | 中 | Operational | — | 1 |
| 排污阀堵塞/卡涩 ▸ 展开▸ expand | 5 | 5 | 3 | 中 | Operational | — | 1 |
判定：Decision: exempt_carbon_steel — 碳钢件豁免 PMI（记录在案），API RP 578 §4
| 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-QT-201A-C08 | CBM | 状态监测/点检（泵汽蚀） | 1960 | 46200 | 10.7% | prior-template | |
| ITPM-QT-201A-R02 | CBM | 基于状态（On-Condition）工单（派生）：泵汽蚀 | 1960 | 46200 | 10.7% | prior-template | |
| ITPM-QT-201A-C05 | CBM | 状态监测/点检（喷嘴堵塞） | 1960 | 37400 | 10.7% | prior-template | |
| ITPM-QT-201A-C06 | CBM | 状态监测/点检（喷嘴腐蚀→雾化不良） | 1960 | 33000 | 12.5% | prior-template | |
| ITPM-QT-201A-C07 | CBM | 状态监测/点检（填料堵塞/结垢） | 1960 | 37400 | 10.7% | prior-template | |
| ITPM-QT-201A-C09 | CBM | 状态监测/点检（机械密封泄漏） | 1960 | 149600 | 10.7% | prior-template | |
| ITPM-QT-201A-C10 | CBM | 状态监测/点检（结垢→换热下降） | 1960 | 37400 | 12.5% | prior-template | |
| ITPM-QT-201A-C12 | CBM | 状态监测/点检（液位计堵塞→溢流/抽空） | 1960 | 41800 | 10.7% | prior-template | |
| ITPM-QT-201A-C13 | CBM | 状态监测/点检（排污阀堵塞/卡涩） | 1960 | 33000 | 10.7% | prior-template | |
| ITPM-QT-201A-C11 | CBM | 状态监测/点检（管束腐蚀泄漏） | 1960 | 167200 | 10.7% | prior-template | |
| ITPM-QT-201A-R03 | CBM | 基于状态（On-Condition）工单（派生）：管束腐蚀泄漏 | 1960 | 167200 | 10.7% | prior-template | |
| ITPM-QT-201A-C04 | CBM | 状态监测/点检（衬里脱落） | 1960 | 41800 | 10.7% | prior-template | |
| ITPM-QT-201A-C03 | CBM | 状态监测/点检（酸露点腐蚀） | 1960 | 50600 | 10.7% | prior-template | |
| ITPM-QT-201A-R01 | CBM | 基于状态（On-Condition）工单（派生）：酸露点腐蚀 | 1960 | 50600 | 10.7% | prior-template | |
| ITPM-QT-201A-I01 | I | UT 测厚网格扫查 | 24 | 0 | — | prior-template | |
| ITPM-QT-201A-I02 | I | UT 定点测厚 | 24 | 0 | — | prior-template | |
| ITPM-QT-201A-P14 | PM | 每周监测塔壁温度，确保高于酸露点温度 | 12 | 0 | — | prior-template | |
| ITPM-QT-201A-P15 | PM | 每季度超声波测厚检查壁厚减薄量 | 12 | 0 | — | prior-template | |
| ITPM-QT-201A-P16 | PM | 每半年更换腐蚀挂片并分析腐蚀速率 | 12 | 0 | — | prior-template | |
| ITPM-QT-201A-P17 | PM | 每月敲击检查衬里空鼓面积 | 12 | 0 | — | prior-template | |
| ITPM-QT-201A-P18 | PM | 每季度红外热成像检测局部温度异常 | 12 | 0 | — | prior-template | |
| ITPM-QT-201A-P19 | PM | 每次停车目视检查衬里表面裂纹或鼓起 | 12 | 0 | — | prior-template | |
| ITPM-QT-201A-P20 | PM | 每3个月拆检清洗喷嘴 | 12 | 0 | — | prior-template | |
| ITPM-QT-201A-P21 | PM | 每班次记录喷淋压力与流量，偏差超10%报警 | 12 | 0 | — | prior-template | |
| ITPM-QT-201A-P22 | PM | 每6个月检查喷嘴孔径和表面状态 | 12 | 0 | — | prior-template | |
| ITPM-QT-201A-P23 | PM | 每季度监测雾化粒径分布 | 12 | 0 | — | prior-template | |
| ITPM-QT-201A-P24 | PM | 每日监测塔压降，趋势分析 | 12 | 0 | — | prior-template | |
| ITPM-QT-201A-P25 | PM | 每季度检查填料外观和重量 | 12 | 0 | — | prior-template | |
| ITPM-QT-201A-P26 | PM | 连续监测泵出口压力和入口压力 | 12 | 0 | — | prior-template | |
| ITPM-QT-201A-P27 | PM | 每日听诊泵体异常噪音 | 12 | 0 | — | prior-template | |
| ITPM-QT-201A-P28 | PM | 每日目视检查泄漏滴漏 | 12 | 0 | — | prior-template | |
| ITPM-QT-201A-P29 | PM | 连续监测密封冲洗液压力 | 12 | 0 | — | prior-template | |
| ITPM-QT-201A-P30 | PM | 建立SIL评估（按IEC 61511）确定安全完整性等级 | 12 | 0 | — | prior-template | |
| ITPM-QT-201A-P31 | PM | 每1个月执行proof test验证保护层有效性 | 12 | 0 | — | prior-template | |
| ITPM-QT-201A-P32 | PM | 每6个月化学清洗换热器 | 12 | 0 | — | prior-template | |
| ITPM-QT-201A-P33 | PM | 每周记录进出口温差和压降 | 12 | 0 | — | prior-template | |
| ITPM-QT-201A-P34 | PM | 每季度超声波测厚管束壁厚 | 12 | 0 | — | prior-template | |
| ITPM-QT-201A-P35 | PM | 每年压力试验或氦检漏 | 12 | 0 | — | prior-template | |
| ITPM-QT-201A-P36 | PM | 每月冲洗引压管 | 12 | 0 | — | prior-template | |
| ITPM-QT-201A-P37 | PM | 每周对比液位计与现场玻璃板读数 | 12 | 0 | — | prior-template | |
| ITPM-QT-201A-P38 | PM | 每月手动操作检查灵活性 | 12 | 0 | — | prior-template | |
| ITPM-QT-201A-P39 | PM | 每季度检查阀杆行程指示 | 12 | 0 | — | prior-template |
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).
本设备 11/11 个 FM 已落 RCM 维修决策；分布：11/11 FMs have RCM decisions; distribution: CBM 9 RTF 2 工程推导eng. infer
| FMFM | 决策Decision | 策略Strategy | 推荐任务Task | 间隔Interval |
|---|---|---|---|---|
| 酸露点腐蚀 | CBM | 视情维修(On-Condition) | 温度/红外热成像监测, 超温报警与根因排查; 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) |
| 泵汽蚀 | CBM | 视情维修(On-Condition) | 入口压力/温度监测 + 叶轮表面蚀坑检查, 优化 NPSH 工况; 按压差/效率监测设定清洗周期 + 过滤/防堵维护 | 高风险 1-3 月 / 中风险 6-12 月 / 低风险 检修期 (按 RBI 风险定级) |
| 管束腐蚀泄漏 | 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) |
ITPM 总工单 42 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 42 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.
| MIQA 状态MIQA Status | in_service |
| 完整性等级Integrity Level | 2 / 5 |
| 上次全面检验Last Full Inspection | 2025-09 |
| 下次检验到期Next Inspection Due | 2027-09 |
| MOC 关联MOC Link | MOC-OPC-QT-201A |
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.