设备完整性一页纸Asset Integrity One-Pager · SC-101 · 螺杆压缩机SC-101 · Screw Compressor

类型Type：螺杆压缩机Screw Compressor · 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.
中推算est.
关键性等级Criticality Class
4 / 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)
0
高风险 FM (S≥8 或 O≥8)High-risk FM (S≥8 or O≥8)
42
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 0 个为高风险（S≥8 或 O≥8）。 主导风险来自「轴封泄漏（工艺气）」（S=7, O=3, AP=低）。 主要失效机理：阴/阳转子型线因润滑不良磨损，间隙增大容积效率下降（API 619 转子要求）, 同步齿轮错位使阴阳转子接触擦伤（API 619 同步要求）, 径向滑动轴承因油膜涡动/疲劳失效（API 619 轴承规范）。 RCM 维修决策以 CBM 为主（CBM 11 / PM 3 / RTF 0）。 当前无高风险 FM，维持既定 ITPM 周期即可。This equipment has 14 failure modes (FM), of which 0 are high-risk (S≥8 or O≥8). The dominant risk is '轴封泄漏（工艺气）' (S=7, O=3, AP=低). Main failure mechanisms: 阴/阳转子型线因润滑不良磨损，间隙增大容积效率下降（API 619 转子要求）, 同步齿轮错位使阴阳转子接触擦伤（API 619 同步要求）, 径向滑动轴承因油膜涡动/疲劳失效（API 619 轴承规范）. RCM maintenance decisions are dominated by CBM (CBM 11 / PM 3 / RTF 0). No high-risk FMs at present; maintain the established ITPM interval.

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
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
后果类型Consequence Type
检验有效性Inspection Effectiveness
置信度Confidence
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

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 0 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
转子型线磨损 ▸ 展开▸ expand644中Operational阴/阳转子型线因润滑不良磨损，间隙增大容积效率下降（API 619 转子要求）1
轴封泄漏（工艺气） ▸ 展开▸ expand733低Operational,Environmental,Safety干气密封端面磨损致工艺气外泄（API 619 密封条款）1
转子接触擦伤 ▸ 展开▸ expand723低Operational,Safety同步齿轮错位使阴阳转子接触擦伤（API 619 同步要求）1
滑动轴承缺陷 ▸ 展开▸ expand634低Operational径向滑动轴承因油膜涡动/疲劳失效（API 619 轴承规范）1
止推轴承失效 ▸ 展开▸ expand723低Operational,Safety止推瓦块因轴向过载烧瓦（API 619 轴向负荷）1
排气温度过高 ▸ 展开▸ expand633低Operational,Safety排气温度超限致润滑油碳化/密封老化（API 619 温度限制）1
振动高（不平衡） ▸ 展开▸ expand543中Operational质量不平衡诱发 1× 振动（ISO 1940/GB-T 6075）1
内部增速齿轮失效 ▸ 展开▸ expand723低Operational,Safety内部同步/增速齿轮断齿或点蚀（API 619 齿轮条款）1
油系统污染 ▸ 展开▸ expand534低Operational油污染致轴承/转子磨损（ISO 4406）1
油泵失效 ▸ 展开▸ expand623低Operational主/辅油泵失效致油压低联锁停机（API 619 油系统）1
中间冷却器结垢 ▸ 展开▸ expand444中Operational冷却器换热下降，排气温度上升（API 619 冷却器）1
吸气过滤器堵塞 ▸ 展开▸ expand444中Operational吸气阻力增大，流量下降（API 619 进气系统）1
联轴器不对中 ▸ 展开▸ expand533低Operational联轴器不对中产生附加载荷与振动1
气量调节失灵 ▸ 展开▸ expand533低Operational容量调节失效致排气量失控（API 619 调节系统）1

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

判定：Decision: exempt — 非承压金属/结构件，API RP 578 范围外

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

CBM=14 PM=28
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-SC-101-C09CBM状态监测/点检（吸气过滤器堵塞）300011000012.6%prior-template
ITPM-SC-101-C08CBM状态监测/点检（中间冷却器结垢）300011000013.1%prior-template
ITPM-SC-101-C10CBM状态监测/点检（排气温度过高）30001100006.3%prior-template
ITPM-SC-101-C04CBM状态监测/点检（止推轴承失效）30001100003.9%prior-template
ITPM-SC-101-C06CBM状态监测/点检（油泵失效）30001100003.9%prior-template
ITPM-SC-101-C07CBM状态监测/点检（轴封泄漏（工艺气））30001100006.8%prior-template
ITPM-SC-101-C05CBM状态监测/点检（油系统污染）30001100008.6%prior-template
ITPM-SC-101-C13CBM状态监测/点检（气量调节失灵）30001100007.2%prior-template
ITPM-SC-101-C02CBM状态监测/点检（转子接触擦伤）30001100003.4%prior-template
ITPM-SC-101-C14CBM状态监测/点检（内部增速齿轮失效）30001100003.4%prior-template
ITPM-SC-101-C01CBM状态监测/点检（转子型线磨损）300011000010.4%prior-template
ITPM-SC-101-C12CBM状态监测/点检（振动高（不平衡））300011000011.3%prior-template
ITPM-SC-101-C11CBM状态监测/点检（联轴器不对中）30001100007.7%prior-template
ITPM-SC-101-C03CBM状态监测/点检（滑动轴承缺陷）30001100007.2%prior-template
ITPM-SC-101-P15PM间隙监测120—prior-template
ITPM-SC-101-P16PM油液分析120—prior-template
ITPM-SC-101-P17PM同步齿轮检查120—prior-template
ITPM-SC-101-P18PM振动监测120—prior-template
ITPM-SC-101-P19PM油膜涡动监测120—prior-template
ITPM-SC-101-P20PM轴振/瓦振120—prior-template
ITPM-SC-101-P21PM轴向位移监测120—prior-template
ITPM-SC-101-P22PM推力瓦温120—prior-template
ITPM-SC-101-P23PM油液颗粒度分析120—prior-template
ITPM-SC-101-P24PM过滤器压差120—prior-template
ITPM-SC-101-P25PM油泵状态监测120—prior-template
ITPM-SC-101-P26PM双泵冗余120—prior-template
ITPM-SC-101-P27PM密封气流量监测120—prior-template
ITPM-SC-101-P28PM泄漏检测120—prior-template
ITPM-SC-101-P29PM端差监测120—prior-template
ITPM-SC-101-P30PM化学清洗120—prior-template
ITPM-SC-101-P31PM过滤器压差报警120—prior-template
ITPM-SC-101-P32PM定期更换120—prior-template
ITPM-SC-101-P33PM排气温度联锁120—prior-template
ITPM-SC-101-P34PM压比核算120—prior-template
ITPM-SC-101-P35PM激光对中120—prior-template
ITPM-SC-101-P36PM振动谐波120—prior-template
ITPM-SC-101-P37PM动平衡120—prior-template
ITPM-SC-101-P38PM振动 1× 趋势120—prior-template
ITPM-SC-101-P39PM调节阀校准120—prior-template
ITPM-SC-101-P40PM负荷响应测试120—prior-template
ITPM-SC-101-P41PM齿轮啮合监测120—prior-template
ITPM-SC-101-P42PM油液铁谱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 11 PM 3 工程推导eng. infer

FM 维修决策样例Sample FM RCM decisions
FMFM决策Decision策略Strategy推荐任务Task间隔Interval
转子型线磨损PM主动维修(Scheduled)绝缘/电气试验 + 继电保护定值校核 + 操动机构特性测试高风险 1-3 月 / 中风险 6-12 月 / 低风险 检修期 (按 RBI 风险定级)
转子接触擦伤CBM视情维修(On-Condition)绝缘/电气试验 + 继电保护定值校核 + 操动机构特性测试; 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)
滑动轴承缺陷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; 绝缘/电气试验 + 继电保护定值校核 + 操动机构特性测试高风险 1-3 月 / 中风险 6-12 月 / 低风险 检修期 (按 RBI 风险定级)
止推轴承失效CBM视情维修(On-Condition)状态监测/定期检查, 按趋势与阈值管理高风险 1-3 月 / 中风险 6-12 月 / 低风险 检修期 (按 RBI 风险定级)
油系统污染CBM视情维修(On-Condition)绝缘/电气试验 + 继电保护定值校核 + 操动机构特性测试; 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)
油泵失效PM主动维修(Scheduled)标定/零点-跨度校验 + SIL Proof test + 阀门行程试验 + 变更管理高风险 1-3 月 / 中风险 6-12 月 / 低风险 检修期 (按 RBI 风险定级)
轴封泄漏（工艺气）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)
中间冷却器结垢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; 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)

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.

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

当前无 S≥8/O≥8 高风险 FM，维持既定 ITPM 周期即可。No S≥8/O≥8 high-risk FMs at present; maintain the established ITPM interval.