设备完整性一页纸Asset Integrity One-Pager · T-101 · 蒸馏塔T-101 · Distillation Column

类型Type：蒸馏塔Distillation Column · 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)
23
失效模式 FM 数Failure Modes (FM)
7
高风险 FM (S≥8 或 O≥8)High-risk FM (S≥8 or O≥8)
102
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 23 个失效模式（FM），其中 7 个为高风险（S≥8 或 O≥8）。 主导风险来自「应力腐蚀开裂 (SCC)」（S=10, O=6, AP=高）。 主要失效机理：均匀腐蚀/氧化, 疲劳, 冲蚀/磨损, SCC（应力腐蚀）。 RCM 维修决策以 CBM 为主（CBM 19 / PM 2 / 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 23 failure modes (FM), of which 7 are high-risk (S≥8 or O≥8). The dominant risk is '应力腐蚀开裂 (SCC)' (S=10, O=6, AP=高). Main failure mechanisms: 均匀腐蚀/氧化, 疲劳, 冲蚀/磨损, SCC（应力腐蚀）. RCM maintenance decisions are dominated by CBM (CBM 19 / PM 2 / 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.

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

材质Material壳体碳钢/塔盘不锈钢
介质Service Fluid工艺介质/回流
设计温度/压力Design T/P120 ℃ / 1.2 MPa
名义壁厚/最小允许Nominal/Min WT16.0 / 11.0 mm
上次检验Last Inspection2025-09
损伤机理Damage Mechanisms均匀腐蚀/氧化、疲劳、冲蚀/磨损、SCC（应力腐蚀）
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.)0.330 mm/yr
壁厚历史趋势（mm）Wall-thickness history trend (mm)
11.010.7
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 23 个 FM，其中Total {len(fms)} FMs, of which 7 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
应力腐蚀开裂 (SCC) ▸ 展开▸ expand1065高Operational—1
焊缝裂纹 (Weld Crack) ▸ 展开▸ expand965高Operational—1
内部腐蚀减薄 (Internal Corrosion Thinning) ▸ 展开▸ expand953中Operational—1
氢致开裂/鼓泡 (HIC/HB) ▸ 展开▸ expand865中Operational—1
管束腐蚀泄漏 (Tube Leak) ▸ 展开▸ expand953中Safety—1
管束腐蚀穿孔 (Tube Perforation) ▸ 展开▸ expand853中Safety—1
液泛 (Flooding) ▸ 展开▸ expand843中Operational—1
防火层脱落 (Fireproofing Loss) ▸ 展开▸ expand767高Operational—1
接管焊缝裂纹 (Nozzle Weld Crack) ▸ 展开▸ expand765中Safety—1
塔盘腐蚀/减薄 (Tray Corrosion) ▸ 展开▸ expand663中Operational—1
填料腐蚀/变形→压降增大 (Packing Degradation) ▸ 展开▸ expand663中Operational—1
填料结垢/堵塞 (Packing Fouling) ▸ 展开▸ expand753中Operational—1
管束结垢→传热下降 (Tube Fouling) ▸ 展开▸ expand663中Operational—1
腐蚀 (Corrosion) ▸ 展开▸ expand653中Operational—1
降液管堵塞 (Downcomer Plugging) ▸ 展开▸ expand743中Operational—1
液体分布器堵塞 (Distributor Plugging) ▸ 展开▸ expand653中Operational—1
管束结垢 (Tube Fouling) ▸ 展开▸ expand563中Operational—1
传感器漂移 (Sensor Drift) ▸ 展开▸ expand562中Operational—1
阀芯冲蚀 (Trim Erosion) ▸ 展开▸ expand563中Operational—1
浮阀卡死/脱落 (Valve Sticking) ▸ 展开▸ expand553中Operational—1
定位器故障 (Positioner Failure) ▸ 展开▸ expand452中Operational—1
法兰泄漏 (Flange Leak) ▸ 展开▸ expand533低Safety—1
引压管堵塞 (Impulse Line Blockage) ▸ 展开▸ expand433低Operational—1

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=30 I=4 PM=68
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-T-101-C20CBM状态监测/点检（管束结垢→传热下降 (Tube Fouling)）19603740014.2%prior-template
ITPM-T-101-C22CBM状态监测/点检（管束结垢 (Tube Fouling)）19603300014.2%prior-template
ITPM-T-101-C11CBM状态监测/点检（法兰泄漏 (Flange Leak)）100013200024.4%prior-template
ITPM-T-101-C10CBM状态监测/点检（防火层脱落 (Fireproofing Loss)）2320418003.8%prior-template
ITPM-T-101-C18CBM状态监测/点检（填料结垢/堵塞 (Packing Fouling)）19604180012.5%prior-template
ITPM-T-101-C21CBM状态监测/点检（管束腐蚀泄漏 (Tube Leak)）196016720012.5%prior-template
ITPM-T-101-C23CBM状态监测/点检（管束腐蚀穿孔 (Tube Perforation)）196015840012.5%prior-template
ITPM-T-101-R06CBM基于状态（On-Condition）工单（派生）：管束腐蚀泄漏 (Tube Leak)196016720012.5%prior-template
ITPM-T-101-R07CBM基于状态（On-Condition）工单（派生）：管束腐蚀穿孔 (Tube Perforation)196015840012.5%prior-template
ITPM-T-101-C16CBM状态监测/点检（液泛 (Flooding)）1960462008.9%prior-template
ITPM-T-101-R05CBM基于状态（On-Condition）工单（派生）：液泛 (Flooding)1960462008.9%prior-template
ITPM-T-101-C24CBM状态监测/点检（引压管堵塞 (Impulse Line Blockage)）1960286008.9%prior-template
ITPM-T-101-C17CBM状态监测/点检（填料腐蚀/变形→压降增大 (Packing Degradation)）19603740014.2%prior-template
ITPM-T-101-C19CBM状态监测/点检（液体分布器堵塞 (Distributor Plugging)）19603740012.5%prior-template
ITPM-T-101-C14CBM状态监测/点检（浮阀卡死/脱落 (Valve Sticking)）19603300012.5%prior-template
ITPM-T-101-C15CBM状态监测/点检（降液管堵塞 (Downcomer Plugging)）19604180010.7%prior-template
ITPM-T-101-C26CBM状态监测/点检（阀芯冲蚀 (Trim Erosion)）19603300014.2%prior-template
ITPM-T-101-C25CBM状态监测/点检（传感器漂移 (Sensor Drift)）19603300012.5%prior-template
ITPM-T-101-C27CBM状态监测/点检（定位器故障 (Positioner Failure)）19602860012.5%prior-template
ITPM-T-101-C07CBM状态监测/点检（焊缝裂纹 (Weld Crack)）2320506003.8%prior-template
ITPM-T-101-C12CBM状态监测/点检（接管焊缝裂纹 (Nozzle Weld Crack)）23201496003.8%prior-template
ITPM-T-101-R03CBM基于状态（On-Condition）工单（派生）：焊缝裂纹 (Weld Crack)2320506003.8%prior-template
ITPM-T-101-C05CBM状态监测/点检（内部腐蚀减薄 (Internal Corrosion Thinning)）2200506006.5%prior-template
ITPM-T-101-C09CBM状态监测/点检（腐蚀 (Corrosion)）2200374006.5%prior-template
ITPM-T-101-R01CBM基于状态（On-Condition）工单（派生）：内部腐蚀减薄 (Internal Corrosion Thinning)2200506006.5%prior-template
ITPM-T-101-C13CBM状态监测/点检（塔盘腐蚀/减薄 (Tray Corrosion)）2320374003.8%prior-template
ITPM-T-101-C06CBM状态监测/点检（应力腐蚀开裂 (SCC)）2320550003.8%prior-template
ITPM-T-101-C08CBM状态监测/点检（氢致开裂/鼓泡 (HIC/HB)）2320462003.8%prior-template
ITPM-T-101-R02CBM基于状态（On-Condition）工单（派生）：应力腐蚀开裂 (SCC)2320550003.8%prior-template
ITPM-T-101-R04CBM基于状态（On-Condition）工单（派生）：氢致开裂/鼓泡 (HIC/HB)2320462003.8%prior-template
ITPM-T-101-I01IUT 测厚网格扫查240—prior-template
ITPM-T-101-I02I表面 MT/PT 探伤（应力集中部位）240—prior-template
ITPM-T-101-I03IUT 定点测厚240—prior-template
ITPM-T-101-I04IPT + 涡流（奥氏体不锈钢敏感部位）240—prior-template
ITPM-T-101-P28PM定期测厚120—prior-template
ITPM-T-101-P29PM检查腐蚀速率120—prior-template
ITPM-T-101-P30PM分析介质腐蚀性120—prior-template
ITPM-T-101-P31PM定期无损检测120—prior-template
ITPM-T-101-P32PM控制应力水平120—prior-template
ITPM-T-101-P33PM监测环境腐蚀性120—prior-template
ITPM-T-101-P34PM建立SIL评估（按IEC 61511）确定安全完整性等级120—prior-template
ITPM-T-101-P35PM每1个月执行proof test验证保护层有效性120—prior-template
ITPM-T-101-P36PM定期焊缝检测120—prior-template
ITPM-T-101-P37PM控制焊接质量120—prior-template
ITPM-T-101-P38PM消除应力120—prior-template
ITPM-T-101-P39PM定期超声波检测120—prior-template
ITPM-T-101-P40PM控制H2S浓度120—prior-template
ITPM-T-101-P41PM使用抗氢钢120—prior-template
ITPM-T-101-P42PM定期检查裙座底部120—prior-template
ITPM-T-101-P43PM防腐涂层维护120—prior-template
ITPM-T-101-P44PM改善排水120—prior-template
ITPM-T-101-P45PM定期检查防火层120—prior-template
ITPM-T-101-P46PM修复脱落部位120—prior-template
ITPM-T-101-P47PM防止机械损伤120—prior-template
ITPM-T-101-P48PM定期检查法兰密封120—prior-template
ITPM-T-101-P49PM紧固螺栓120—prior-template
ITPM-T-101-P50PM更换垫片120—prior-template
ITPM-T-101-P51PM控制热应力120—prior-template
ITPM-T-101-P52PM改善焊接工艺120—prior-template
ITPM-T-101-P53PM定期检查塔盘厚度120—prior-template
ITPM-T-101-P54PM更换腐蚀严重塔盘120—prior-template
ITPM-T-101-P55PM优化操作条件120—prior-template
ITPM-T-101-P56PM定期检查浮阀活动性120—prior-template
ITPM-T-101-P57PM清洗浮阀及塔盘120—prior-template
ITPM-T-101-P58PM更换卡死或脱落的浮阀120—prior-template
ITPM-T-101-P59PM定期检查降液管入口和出口120—prior-template
ITPM-T-101-P60PM清理沉积物120—prior-template
ITPM-T-101-P61PM使用在线清洗或化学清洗120—prior-template
ITPM-T-101-P62PM定期检查塔盘压降120—prior-template
ITPM-T-101-P63PM调整操作气速120—prior-template
ITPM-T-101-P64PM优化操作参数120—prior-template
ITPM-T-101-P65PM定期检查填料状态120—prior-template
ITPM-T-101-P66PM更换腐蚀或变形的填料120—prior-template
ITPM-T-101-P67PM优化操作温度120—prior-template
ITPM-T-101-P68PM定期检查填料结垢情况120—prior-template
ITPM-T-101-P69PM化学清洗或更换填料120—prior-template
ITPM-T-101-P70PM过滤进料固体颗粒120—prior-template
ITPM-T-101-P71PM定期检查液体分布器孔口120—prior-template
ITPM-T-101-P72PM清理堵塞物120—prior-template
ITPM-T-101-P73PM更换损坏的分布器120—prior-template
ITPM-T-101-P74PM定期检查再沸器管束结垢120—prior-template
ITPM-T-101-P75PM化学清洗或机械清洗120—prior-template
ITPM-T-101-P76PM优化水质处理120—prior-template
ITPM-T-101-P77PM定期进行管束测厚120—prior-template
ITPM-T-101-P78PM检查腐蚀介质120—prior-template
ITPM-T-101-P79PM更换泄漏管束120—prior-template
ITPM-T-101-P80PM定期检查冷凝器管束结垢120—prior-template
ITPM-T-101-P81PM优化冷却水处理120—prior-template
ITPM-T-101-P82PM定期进行管束涡流检测120—prior-template
ITPM-T-101-P83PM更换穿孔管束120—prior-template
ITPM-T-101-P84PM定期检查引压管120—prior-template
ITPM-T-101-P85PM吹扫或清洗引压管120—prior-template
ITPM-T-101-P86PM安装隔离罐或吹气装置120—prior-template
ITPM-T-101-P87PM定期校准差压变送器120—prior-template
ITPM-T-101-P88PM检查传感器老化120—prior-template
ITPM-T-101-P89PM更换漂移传感器120—prior-template
ITPM-T-101-P90PM定期检查阀芯冲蚀情况120—prior-template
ITPM-T-101-P91PM更换冲蚀阀芯120—prior-template
ITPM-T-101-P92PM优化流体速度或材质120—prior-template
ITPM-T-101-P93PM定期检查定位器120—prior-template
ITPM-T-101-P94PM清洁气源和电气连接120—prior-template
ITPM-T-101-P95PM更换故障定位器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 23/23 个 FM 已落 RCM 维修决策；分布：23/23 FMs have RCM decisions; distribution: CBM 19 PM 2 RTF 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
内部腐蚀减薄 (Internal Corrosion Thinning)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)
应力腐蚀开裂 (SCC)CBM视情维修(On-Condition)无损检测(UT/VT/MT/PT), 按 API 581 RBI 风险定级设定检验间隔; 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)
焊缝裂纹 (Weld Crack)CBM视情维修(On-Condition)无损检测(UT/VT/MT/PT), 按 API 581 RBI 风险定级设定检验间隔; 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)
氢致开裂/鼓泡 (HIC/HB)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)
液泛 (Flooding)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 (Tube Leak)CBM视情维修(On-Condition)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)
管束腐蚀穿孔 (Tube Perforation)RTF设计改进/探测任务(Redesign)温度/红外热成像监测, 超温报警与根因排查; 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 102 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 102 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-T-101
建议优先级Recommended Priority

存在 7 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 7 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.